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Matched Legal Cases: ['arts                             73', 'arts                             20', 'arts                             6', 'arts                             0', 'arts                             60', 'arts                             33', 'arts                             3', 'arts                             3', 'arts                             60', 'arts                             33', 'arts                             3', 'arts                             3']

Patent US5863305 - Method and apparatus for manufacturing abrasive articles - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsA method for making a nonwoven a abrasive article. A preferred aspect of the method comprises the steps of: a) providing a nonwoven web having a first side and a second side, the web comprising a plurality of fibers; b) frothing a liquid make coat precursor; c) applying the frothed make coat precursor...http://www.google.com/patents/US5863305?utm_source=gb-gplus-sharePatent US5863305 - Method and apparatus for manufacturing abrasive articlesAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS5863305 APublication typeGrantApplication numberUS 08/930,098PCT numberPCT/US1996/006276Publication dateJan 26, 1999Filing dateMay 3, 1996Priority dateMay 3, 1996Fee statusPaidAlso published asDE69618022D1, DE69618022T2, EP0912292A1, EP0912292B1, WO1997042003A1Publication number08930098, 930098, PCT/1996/6276, PCT/US/1996/006276, PCT/US/1996/06276, PCT/US/96/006276, PCT/US/96/06276, PCT/US1996/006276, PCT/US1996/06276, PCT/US1996006276, PCT/US199606276, PCT/US96/006276, PCT/US96/06276, PCT/US96006276, PCT/US9606276, US 5863305 A, US 5863305A, US-A-5863305, US5863305 A, US5863305AInventorsKris A. Beardsley, Jonathan M. Lise, Brent D. Niccum, Rufus C. Sanders, Jr.Original AssigneeMinnesota Mining And Manufacturing CompanyExport CitationBiBTeX, EndNote, RefManPatent Citations (99), Non-Patent Citations (2), Referenced by (28), Classifications (9), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetMethod and apparatus for manufacturing abrasive articles
It has also been suggested to apply the make coat precursor without abrasive particles, and thereafter apply the abrasive particles. Suggested methods of applying the abrasive particles include drop coating, electrostatic coating, and spray methods similar to those used in sand blasting except with milder conditions. See, for example, U.S. Pat. No. 4,227,350 to Fitzer, and U.S. Pat. No. 5,363,604 to Heyer.
It is desirable to solve the above described problem and to thereby fulfill a long felt need relating to the optimization of fine abrasive particle distribution in nonwoven surface treating articles. It is desirable to provide a method of manufacturing nonwoven surface treating articles comprising a nonwoven web with fine abrasive particles adhered to the fibers of the web wherein the particles are distributed along the lengths of the fibers of the web in a substantially uniform manner and wherein an increased percentage of the abrasive particles are immediately available for abrasive applications.
The present invention provides methods and apparatuses for the manufacture of nonwoven abrasive articles, wherein the method utilizes a deposition method to deposit fine abrasive particles onto the fibers of the nonwoven web so that the particles are distributed along the fibers in an abrasively effective manner. The resulting articles include fine abrasive particles adhered to the fibers of a nonwoven web in a desirable particle distribution. The articles are useful in abrasive applications such as finishing and polishing of metal, wood and plastic surfaces, for example, and especially in the automobile aftermarket industry where the articles are useful to treat painted automobile panels and the like.
One aspect of the present invention presents a method for making an abrasive article. The method comprises the steps of: a) providing a nonwoven web having a first side and a second side, the web comprising a plurality of fibers; b) frothing a liquid make coat precursor; c) applying the frothed make coat precursor to at least the first side of the web in such a manner so as to achieve a substantially uniform coating of the make coat precursor along the fibers of the web; d) spraying a plurality of fine abrasive particles onto the first side of the web, wherein the particles are sprayed so as to form a cloud of abrasive particles that deposit onto the fibers of the web in a substantially uniform distribution; and e) curing the make coat precursor to thereby form a hardened make coat which adheres the abrasive particles to the web and wherein the abrasive particles substantially protrude from the outer surface of the hardened make coat.
In one preferred aspect of the above method, step d) comprises spraying the abrasive particles with a particle sprayer having an exit, and directing the abrasive particles in the vicinity of the exit in a direction non-perpendicular to the first side of the web. In one version of this method, the method comprises the further steps of fluidizing a supply of abrasive particles and supplying a fluidized abrasive particle/air mixture to the particle sprayer, prior to spraying the abrasive particles. In another version of this method, step d) comprises directing the abrasive particles with a particle deflector mounted at the exit of the particle sprayer. In another version of this method, step d) comprises directing the abrasive particles with a spinning plate at the exit of the particle sprayer.
In another preferred aspect of the above method, step b) comprises frothing the make coat precursor to a blow ratio of from 2:1 to 99:1. In one version of this method, step b) comprises frothing the make coat precursor to a blow ratio of from 5:1 to 21:1.
In another preferred aspect of the above method, the method comprises the further steps of, subsequent to step d), applying a liquid size coat precursor so as to substantially cover the make coat precursor and abrasive particles in such a manner that the abrasive particles coated with size coat precursor substantially protrude from the fibers of the web and thereafter curing the size coat precursor. In one version of this method, the method comprises the further step of frothing the size coat precursor to a blow ratio of from 2:1 to 99:1 prior to applying it the web.
The present invention also presents another method for making an abrasive article. This method comprises the steps of: a) providing a nonwoven web having a first side and a second side, the web comprising a plurality of fibers; b) frothing a liquid make coat precursor to a blow ratio of from 2:1 to 99:1; c) applying the frothed make coat precursor to at least the first side of the web in such a manner so as to achieve a substantially uniform coating of the make coat precursor along the fibers of the web; d) spraying a plurality of fine abrasive particles with a particle sprayer having an exit and directing the abrasive particles in the vicinity of the exit in a direction non-perpendicular to the first side of the web, wherein the particles are sprayed so as to form a cloud of abrasive particles that deposit onto the fibers of the web in a substantially uniform distribution; e) frothing a liquid size coat precursor to a blow ratio of from 2:1 to 99:1; f) applying the frothed size coat precursor so as to substantially cover the make coat precursor and abrasive particles in such a manner that the abrasive particles coated with size coat precursor substantially protrude from the fibers of the web; and g) curing the make coat precursor and size coat precursor to thereby form a hardened coating which adheres the abrasive particles to the web.
In one version, the above method comprises the further step prior to step f) of at least partially curing the make coat precursor.
In another version of the above method, step b) comprises frothing the make coat precursor to a blow ratio of from 5:1 to 21:1; and step e) comprises frothing the size coat precursor to a blow ratio of from 5:1 to 21:1.
In yet another version, the above method comprises the further steps of fluidizing a supply of abrasive particles and supplying a fluidized abrasive particle/air mixture to the particle sprayer, prior to spraying the abrasive particles.
The present invention also presents a further method for making an abrasive article. This method comprises the steps of a) providing a nonwoven web having a first side and a second side, the web comprising a plurality of fibers; b) applying the a make coat precursor to at least the first side of the web in such a manner so as to achieve a substantially uniform coating of the make coat precursor along the fibers of the web; c) spraying a plurality of fine abrasive particles with a particle sprayer having an exit and directing the abrasive particles in the vicinity of the exit in a direction non-perpendicular to the first side of the web, wherein the particles are sprayed so as to form a cloud of abrasive particles that deposit onto the fibers of the web in a substantially uniform distribution; and d) curing the make coat precursor to thereby form a hardened make coat which adheres the abrasive particles to the web and wherein the abrasive particles substantially protrude from the outer surface of the hardened make coat.
In one version of the above method, step c) comprises directing the abrasive particles with a particle deflector mounted at the exit of the particle sprayer.
In another version of the above method step c) comprises directing the abrasive particles with a spinning plate at the exit of the particle sprayer.
In yet another version, the above method comprises the further steps of, subsequent to step c), applying a size coat precursor so as to substantially cover the make coat precursor and abrasive particles in such a manner that the abrasive particles coated with size coat precursor substantially protrude from the fibers of the web and thereafter curing the size coat precursor.
In still another version, the above method comprises the further steps of fluidizing a supply of abrasive particles and supplying a fluidized abrasive particle/air mixture to the particle sprayer, prior to spraying the abrasive particles.
The present invention also presents still a further method for making an abrasive article. This method comprises the steps of: a) providing a nonwoven web having a first side and a second side, the web comprising a plurality of fibers; b) frothing a liquid make coat precursor; c) applying the frothed make coat precursor to at least the first side of the web in such a manner so as to achieve a substantially uniform coating of the make coat precursor along the fibers of the web; d) applying a plurality of fine abrasive particles onto the first side of the web, wherein the particles are applied in a substantially uniform distribution along the fibers of the web; and e) curing the make coat precursor to thereby form a hardened make coat which adheres the abrasive particles to the web and wherein the abrasive particles substantially protrude from the outer surface of the hardened make coat.
In one aspect of the above method, step b) comprises frothing the make coat precursor to a blow ratio of from 2:1 to 99:1. In one version of this method, step b) comprises frothing the make coat precursor to a blow ratio of from 5:1 to 21:1.
In another aspect, the above method comprises the further steps of, subsequent to step d), applying a liquid size coat precursor so as to substantially cover the make coat precursor and abrasive particles in such a manner that the abrasive particles coated with size coat precursor substantially protrude from the fibers of the web and thereafter curing the size coat precursor. In one version of this method, the method comprises the further step of frothing the size coat precursor to a blow ratio of from 2:1 to 99:1 prior to applying it the web.
The present invention presents still another method for making an abrasive article. This method comprises the steps of: a) providing a nonwoven web having a first side and a second side, the web comprising a plurality of fibers; b) frothing a liquid make coat precursor; c) applying the frothed make coat precursor to at least the first side of the web in such a manner so as to achieve a substantially uniform coating of the make coat precursor along the fibers of the web; d) spraying a plurality of abrasive particles onto the first side of the web, wherein the particles are sprayed so as to form a cloud of abrasive particles that deposit onto the fibers of the web in a substantially uniform distribution; and e) curing the make coat precursor to thereby form a hardened make coat which adheres the abrasive particles to the web and wherein the abrasive particles substantially protrude from the outer surface of the hardened make coat.
In one aspect of the above method, step d) comprises spraying the abrasive particles with a particle sprayer having an exit, and directing the abrasive particles in the vicinity of the exit in a direction non-perpendicular to the first side of the web. In one version of this method, the method comprises the further steps of fluidizing a supply of abrasive particles and supplying a fluidized abrasive particle/air mixture to the particle sprayer, prior to spraying the abrasive particles. In another version of this method, step d) comprises directing the abrasive particles with a particle deflector mounted at the exit of the particle sprayer. In still another version, step d) comprises directing the abrasive particles with a spinning plate at the exit of the particle sprayer.
In another aspect, the above method comprises the further steps of, subsequent to step d), applying a liquid size coat precursor so as to substantially cover the make coat precursor and abrasive particles in such a manner that the abrasive particles coated with size coat precursor substantially protrude from the fibers of the web and thereafter curing the size coat precursor. In one version of this method, the method comprises the further step of frothing the size coat precursor prior to applying it the web.
Certain terms are used in the description and the claims that, while for the most part are well known, may require some explanation. In describing the present invention, "prebond resin" refers to a coatable resinous adhesive applied directly to the fibers of an unbonded nonwoven web in order to bond the fibers together at their mutual contact points. "Prebonded web" refers to a nonwoven web wherein the fibers of the web have been treated with a prebond resin and the resin has been hardened to bond the fibers at their mutual contact points. "Make coat precursor" refers to the coatable resinous adhesive material applied to the fibers of the nonwoven web to secure abrasive particles thereto. "Make coat" refers to the layer of hardened resin over the fibers of the nonwoven web formed by hardening the make coat precursor. "Size coat precursor" refers to the coatable resinous adhesive material applied to the fibers of the nonwoven web over the make coat. "Size coat" refers to the layer of hardened resin over the fibers of the nonwoven web formed by hardening the size coat precursor. "Cured" or "fully cured" means a hardened polymerized curable coatable resin. "Fiber" refers to a threadlike structure. "Fine abrasive particles" refers to abrasively effective particles comprising any of the materials set forth herein and having distribution of particle sizes wherein the median particle diameter is about 60 microns or less. A spherical particle shape is assumed in referring to the median particle diameter, based on standard test methods available for the determination of particle diameters, such as, for example, ANSI test method B74.18-1984. "Substantially uniform" in referring to the distribution of fine abrasive particles along the length of the fibers means that the particles in the finished articles are distributed along the lengths of the fibers without significant agglomeration of the resin and the particles, as may be visually observed by microscopic examination of the fibers. In the finished article, the majority of the particles are positioned along the fibers to be abrasively effective in the initial application of the article.
FIG. 1 is an enlarged view of a portion of a prior art surface treating article showing individual fibers of a nonwoven web;
FIG. 2 is a partially schematic view of a method and apparatus for manufacturing lofty nonwoven abrasive articles according to the present invention;
FIG. 3 is a partially schematic view of one embodiment of a particle coater according to the present invention;
FIG. 4 is an enlarged view of a portion of a surface treating article showing individual fibers with abrasive particles adhered to the surface of the fibers manufactured according to the method of the present invention;
FIG. 2 illustrates partially schematically a first embodiment of an apparatus and method for manufacturing abrasive articles according to the present invention. The method comprises, in summary, the following. Lofty nonwoven web or substrate 100 having first side 104 and second side 106 is fed into apparatus 14. The web 100 passes through first adhesive or make coat precursor coater 20. The web 100 then passes through the first abrasive particle coater 22 which applies abrasive particles 102 at least to the first side 104 of the web 100. When it is desired to apply abrasive particles to the second side 106 of the web 100, the web passes around rollers 24a and 24b so as to be inverted to have second side 106 facing up. The inverted web 100 then passes through optional second abrasive particle coater 26. After the abrasive particles are applied, the make coat precursor preferably is at least partially cured, and may optionally be fully cured. The web then passes through second adhesive or size coat precursor coater 28. The coated web 100 is then fully cured as is known in the art. Preferably, the web 100 is conveyed on carrier belts throughout apparatus 14, except where the web passes from roller 24a to 24b as described above. The configuration and operation of such carrier belts is within the skill of those practicing in the art, and have been omitted from the figures for clarity.
A preferred web 100 for use with the present invention comprises an open, lofty, nonwoven web of fibers 100 which preferably have been bonded to one another at their mutual contact points by a cured prebond resin. Alternatively, the web can comprise melt bondable bicomponent fibers wherein the fibers are of a sheath-core or side by side configuration and which have been heated to the melting point of at least one component of the fibers to cause melt bonding between the fibers at their contact points. Suitable melt bondable fibers include those described by Hayes et al. in U.S. Pat. No. 5,082,720. A plurality of fine abrasive particles 102 are bonded to the fibers 100 by cured resinous binders applied to the web to provide make and size coats, as described herein. The abrasive particles 102 are arranged in a preferred distribution along the fibers 100 so that the particles 102 are distributed in a substantially uniform manner along the fibers and without burying the fibers in agglomerated resin. In this construction, the particles 102 are positioned to be immediately effective in initial abrasive applications of the finished article, such as in the treatment of painted automobile body panels, for example.
The nonwoven web suitable for use in the articles of the invention may be made of an air-laid, carded, stitch-bonded, spunbonded, wet laid, or melt blown construction. A preferred nonwoven web is the open, lofty, three-dimensional air-laid nonwoven substrate described by Hoover et al. in U.S. Pat. No. 2,958,593. Alternatively, the nonwoven web used herein can be a low density nonwoven article formed of a multiplicity of crimped filaments (e.g., thermoplastic filaments) wherein one end of substantially all of the filaments are bonded together at a first bonding site and a second end of substantially all of the filaments are bonded together at a second bonding site with a nonbonded portion of the filament array in between the first and second bonding sites. Such a nonwoven web is described in U.S. Pat. Nos. 4,991,362 and 5,025,596, both to Heyer et al.
The nonwoven web preferably comprises a first major web surface 104, a second major web surface 106, and a middle web portion extending between the first and second major web surfaces. The web is made of a suitable synthetic fiber capable of withstanding the temperatures at which impregnating resins and adhesive binders are cured without deterioration. Fibers suitable for use in the articles of the invention include natural and synthetic fibers, and mixtures thereof. Synthetic fibers are preferred including those made of polyester (e.g., polyethylene terephthalate), nylon (e.g., hexamethylene adipamide, polycaprolactum), polypropylene, acrylic (formed from a polymer of acrylonitrile), rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymers, vinyl chloride-acrylonitrile copolymers, and so forth. Suitable natural fibers include those of cotton, wool, jute, and hemp. The fiber used may be virgin fibers or waste fibers reclaimed from garment cuttings, carpet manufacturing, fiber manufacturing, or textile processing, for example. The fiber material can be a homogenous fiber or a composite fiber, such as bicomponent fiber (e.g., a co-spun sheath-core fiber). It is also within the scope of the invention to provide an article comprising different fibers in different portions of the web (e.g., the first web portion, the second web portion and the middle web portion). The fibers of the web are preferably tensilized and crimped but may also be continuous filaments formed by an extrusion process such as that described in U.S. Pat. No. 4,227,350 to Fitzer, as well as the continuous fibers described by the aforementioned '362 and '596 patents to Heyer et al.
The aforementioned nonwoven web is readily formed on a "Rando Webber" machine (commercially available from Rando Machine Company, New York) or may be formed by other conventional processes. Where a spunbond-type nonwoven material is employed, the filaments may be of substantially larger diameter, for example, up to 2 millimeters or more in diameter. Useful nonwoven webs preferably have a weight per unit area at least about 50 g/m2, preferably between 50 and 200 g/m2, more preferably between 75 and 150 g/m2. Lesser amounts of fiber within the nonwoven web will provide articles which may be suitable in some applications, but articles with lower fiber weights may have somewhat shorter commercial work lives. The foregoing fiber weights typically will provide a web, before needling or impregnation, having a thickness from about 5 to about 200 millimeters, typically between 6 to 75 millimeters, and preferably between 10 and 30 millimeters.
Where the web is to be incorporated into machine driven abrasive articles such as endless belts or abrasive discs, a reinforcing fabric backing may be applied and affixed to one of the major surfaces of the web. The reinforcing fabric is preferably a woven stretch-resistant fabric with a low-stretch value when pulled in opposing directions. A stretch value of less than about 20% is preferred and a value of less than about 15% is more preferred. Suitable materials for use as the reinforcing fabric in the articles of the invention include, without limitation, thermobonded fabrics, knitted fabrics, stitch-bonded fabrics and the like. Those skilled in the art will appreciate that the invention is not to be limited to the selection of one reinforcing fabric over another, and it is contemplated that the invention can include any type of material which otherwise has the requisite properties as set forth herein. The fabric backing may be adhesively affixed to the nonwoven web or it may be affixed during the aforementioned needletacking step, all in a known manner. An additional layer comprising a suitable polymer may then be applied over the exposed surface of the fabric backing in the manner described in commonly assigned U.S. Pat. No. 5,482,756, issued Jan. 9, 1996, or in the manner described in commonly assigned U.S. Pat. No. 5,573,844, issued Nov. 12, 1996.
The prebond resin, when used to bond fibers in the web to one-another at their mutual contact points, preferably comprises a coatable resinous adhesive similar or identical to the resin used for the make coat precursor, described below. More preferably, the prebond is made of a thermosetting water based phenolic resin. The prebond is applied to the web in a relatively light coating, typically providing a dry add-on weight within the broad range from about 50 to 200 g/m2 for phenolic prebond resins applied to a nonwoven web having a fiber weight within the above ranges. Polyurethane resins may also be employed as well as other resins, and those skilled in the art will appreciate that the selection and amount of resin actually applied can depend on any of a variety of factors including, for example, the fiber weight in the nonwoven web, the fiber density, the fiber type as well as the contemplated end use for the finished article. Of course, the present invention does not require the use of a prebond resin and the invention is not to be construed as being limited to nonwoven webs comprising any particular prebond resin.
As seen in FIG. 2, the lofty nonwoven web 100 preferably as described above and having first side 104 and second side 106 is fed into apparatus 14. At this stage, the nonwoven web 100 is preferably a pre-bonded web, not yet comprising abrasive particles. As is described in more detail below, an adhesive layer is formed from the application to the web of a resinous make coat precursor or first resin and, optionally, a size coat precursor or second resin applied over the make coat precursor. Preferably, the adhesive layer is formed from the make coat precursor and the size coat precursor which have been applied to the web at a coating weight which, when hardened, provides the necessary adhesion to strongly bond abrasive particles to the fibers. In the finished articles of the invention, the adhesive layer provides a light coating of resin over the fine abrasive particles without burying the particles within the resin. When observed under a microscope, for example, the individual particles are observed to be anchored to the fibers and to extend outwardly from the outer surfaces of the fibers. In this construction, the fine abrasive particles are positioned in the article to be immediately abrasively effective in the initial applications of the finished article. Moreover, the particles are strongly adhered to the fibers of the web to provide an abrasive article with a satisfactory work life.
The nonwoven web 100 is first passed through coater 20 which applies first adhesive or make coat precursor to the web 100. The coater 20 can comprise any suitable coater known in the art, such as a spray coater, roll coater, dip coater, knife over roll coater, or the like. When applying the preferred foamed make coat precursor described below, the preferred coater 20 comprises a double roll coater with the web 100 passing through the nip formed by the two opposed rollers. Such coaters are well known in the art need not be further described herein. The foamed make coat precursor is applied to the top roller from a frother through a slot die as is known in the art. In one preferred embodiment, the frother is of the type commercially available as a "F2S-8" from SKG Industries, West Lawn, Pa. Other suitable arrangements for applying the frothed make coat precursor to the web include but are not limited to: applying the make coat precursor with a slot die to the bottom roll or to both rolls of a double roll coater; applying the make coat precursor with a slot die directly to the web prior to entering the nip of a double roll coater; applying the make coat precursor with a slot die without a roll coater and optionally by drawing a vacuum across the web opposite the slot die, applying the make coat precursor to both sides of the web with opposed slot dies with or without subsequently passing the web through a roll coater; and applying the make coat precursor with a hose or duct transversing across the web.
The make coat precursor suitable for use in the invention is a coatable, hardenable adhesive binder and may comprise one or more thermoplastic or, preferably, thermosetting resinous adhesives. Resinous adhesives suitable for use in the present invention include phenolic resins, aminoplast resins having pendant α,β-unsaturated carbonyl groups, urethane resins, epoxy resins, ethylenically unsaturated resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, bismaleimide resins, fluorene-modified epoxy resins, and combinations thereof. Catalysts and/or curing agents may be added to the binder precursor to initiate and/or accelerate the polymerization process.
Epoxy resins have an oxirane and are polymerized by the ring opening. Such epoxide resins include monomeric epoxy resins and polymeric epoxy reins. These resin can vary greatly in the nature of their backbones and substituent groups. For example, the backbone may be of any type normally associated with epoxy resins and substituent groups thereon can be any group free of an active hydrogen atom that is reactive with an oxirane ring at room temperature. Representative examples of acceptable substituent groups include halogens, ester groups, ether groups, sulfonate groups, siloxane groups, nitro groups and phosphate groups. Examples of some preferred epoxy resins include 2,2-bis 4-(2,3-epoxypropoxy)-phenyl)propane (diglycidyl ether of bisphenol a)! and commercially available materials under the trade designation "Epon 828", "Epon 1004" and "Epon 1001F" available from Shell Chemical Co., "DER-331", "DER-332" and "DER-334" available from Dow Chemical Co. Other suitable epoxy resins include glycidyl ethers of phenol formaldehyde novolac (e.g., "DEN-431" and "DEN-428" available from Dow Chemical Co.
The aminoplast binder precursors have at least one pendant alpha, beta-unsaturated carbonyl group per molecule or oligomer. These materials are further described in U.S. Pat. Nos. 4,903,440 (Larson et al.) and 5,236,472 (Kirk et al.).
The ethylenically unsaturated monomers or oligomers may be monofunctional, difunctional, trifunctional or tetrafunctional or even higher functionality. The term acrylate includes both acrylates and methacrylates. Ethylenically unsaturated binder precursors include both monomeric and polymeric compounds that contain atoms of carbon, hydrogen and oxygen, and optionally, nitrogen and the halogens. Oxygen or nitrogen atoms or both are generally present in ether, ester, urethane, amide, and urea groups. Ethylenically unsaturated compounds preferably have a molecular weight of less than about 4,000 and are preferably esters made from the reaction of compounds containing aliphatic monohydroxy groups or aliphatic polyhydroxy groups and unsaturated carboxylic acids, such as acrylic acid, methacrylic acid, itaconic acid, crotonic acid, isocrotonic acid, maleic acid, and the like. Representative examples of ethylenically unsaturated monomers include methyl methacrylate, ethyl methacrylate, styrene, divinylbenzene, hydroxy ethyl acrylate, hydroxy ethyl methacrylate, hydroxy propyl acrylate, hydroxy propyl methacrylate, hydroxy butyl acrylate, hydroxy butyl methacrylate, vinyl toluene, ethylene glycol diacrylate, polyethylene glycol diacrylate, ethylene glycol dimethacrylate, hexanediol diacrylate, triethylene glycol diacrylate, trimethylolpropane triacrylate, glycerol triacrylate, pentaerthyitol triacrylate, pentaerythritol trimethacrylate, pentaerythritol tetraacrylate and pentaerythritol tetramethacrylate. Other ethylenically unsaturated resins include monoallyl, polyallyl, and polymethallyl esters and amides of carboxylic acids, such as diallyl phthalate, diallyl adipate, and N,N-diallyladipamide. Still other nitrogen containing compounds include tris(2-acryl-oxyethyl)isocyanurate, 1,3,5-tri(2-methyacryloxyethyl)-s-triazine, acrylamide, methylacrylamide, N-methyl-acrylamide, N,N-dimethylacrylamide, N-vinyl-pyrrolidone, and N-vinyl-piperidone.
Isocyanurate derivatives having at least one pendant acrylate group and isocyanate derivatives having at least one pendant acrylate group are further described in U.S. Pat. No. 4,652,274 (Boettcher et al). The preferred isocyanurate material is a triacrylate of tris(hydroxy ethyl) isocyanurate.
Acrylated urethanes are diacrylate esters of hydroxy terminated isocyanate extended polyesters or polyethers. Examples of commercially available acrylated urethanes include "UVITHANE 782", available from Morton Chemical, and "CMD 6600", "CMD 8400", and "CMD 8805", available from UCB Radcure•Specialties. Acrylated epoxies are diacrylate esters of epoxy resins, such as the diacrylate esters of bisphenol A epoxy resin. Examples of commercially available acrylated epoxies include "CMD 3500", "CMD 3600", and "CMN 3700", available from UCB Radcure Specialties.
Examples of ethylenically unsaturated diluents or monomers can be found in U.S. Pat. No. 5,236,472 (Kirk et al.) and U.S. Ser. No. 08/144,199 (Larson et al.). In some instances these ethylenically unsaturated diluents are useful because they tend to be compatible with water.
Additional details concerning acrylate dispersions can be found in U.S. Pat. No. 5,378,252 (Follensbee).
In the manufacture of hand pads for use in the automotive applications mentioned above, the adhesive materials used as the make coat precursor in the present invention preferably comprise thermosetting phenolic resins such as resole and novolac resins, described in Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Ed. John Wiley & Sons, 1981, New York, Vol. 17, pp. 384-399. Resole phenolic resins are made with an alkaline catalyst and a molar excess of formaldehyde, typically having a molar ratio of formaldehyde to phenol between 1.0:1.0 and 3.0:1.0. Novolac resins are prepared under acid catalysis and with a molar ratio of formaldehyde to phenol less than 1.0:1.0. A typical resole resin useful in the manufacture of articles of the present invention contains between about 0.75% (by weight) and about 1.4% free formaldehyde; between about 6% and about 8% free phenol; about 78% solids with the remainder being water. The pH of such a resin is about 8.5 and the viscosity is between about 2400 and about 2800 centipoise. Commercially available phenolic resins suitable for use in the present invention include those known under the trade designations "Durez" and "Varcum", available from Occidental Chemicals Corporation (N. Tonawonda, N.Y.); "Resinox", available from Monsanto Corporation; and "Arofene" and "Arotap", both available from Ashland Chemical Company; as well as the resole precondensate available under the trade designation "BB077" from Neste Resins, a Division of Neste Canada, Inc., Mississauga, Ontario, Canada. Organic solvent may be added to the phenolic resin as needed or desired.
The foamable, coatable, hardenable resin composition useful as a make coat precursor in the present invention should be able to retain its foam form for a sufficient length of time to allow the application of the foam to the nonwoven web before the foam breaks significantly. Preferably, the foamed make coat will begin to break soon after its application to the nonwoven web so that the application of the abrasive particles can be accomplished in a manner which allows the particles to penetrate into the web beyond the uppermost surface layers of fibers. The resin compositions may be foamed by known methods, such as by mechanically foaming or frothing, by the injection and dispersion of insoluble gas, or by the use of chemical blowing agents that thermally or otherwise decompose to produce a gas-phase material. For the purposes of the present invention, the foamable, coatable, hardenable resin compositions should be foamable to a blow ratio, i.e., the ratio of foamed volume to that of the unfoamed starting material, of between 2:1 and 99:1. Phenolic foamed binder resin dispersions preferably will have a gas content of at least 20% by volume and more preferably between 50% and 99% (or a blow ratio of between 2:1 and 99:1, preferably between 5:1 and 25:1 and more preferably about 10:1). The labile foam must retain its structural integrity at least until the foam is applied to the fibers of the web in order to reduce the wet add-on weight of the resin being applied to the fiber layer. Foaming of the make coat provides a desired and economically attractive reduction in the add-on weight of the resin because the foamed resin is highly diluted with air, significantly increasing the volume of the resin while utilizing a smaller amount than would be required in the absence of foaming. The application of the foamed resin to the fibers of the web creates a substantially uniform monolayer of resin along the lengths of the fibers which, in turn, provides the bonding surface for the fine abrasive particles.
After exiting the first adhesive coater 20, web 100 passes through first particle coater 22. First particle coater 22 is preferably configured to apply abrasive particles 102 to the first surface 104 of the web. As explained further below, the abrasive grains 102 will penetrate from surface 104 to some depth into the web 100. When it is desired to apply abrasive grains to second side 106 of the web 100, the web passes over rollers 24a and 24b so as to re-orient the web to have second side 106 facing up. The web 100 then passes through an optional second particle coater 26 configured to apply abrasive particles 102 to the second side 106 of web 100. Preferably, second particle coater 26 is of like construction as first particle coater 22. However, for certain applications, it may be preferable to use second coater 26 of a different type or configuration from first particle coater 22. Also, the second abrasive particle coater 26 may apply abrasive particles having either the same or different composition and/or size as the abrasive particles applied by the first abrasive particle coater 22.
The abrasive particles suitable for inclusion in the abrasive articles of the present invention include all known fine abrasive particles. Preferably, such fine abrasive particles are provided in a distribution of particle sizes with a median particle diameter of about 60 microns or less. In the preparation of hand pads to be used in the aforementioned automotive applications, the median particle diameter may be smaller than 60 microns. In such articles, a median particle diameter of 40 microns or less is somewhat more preferred. In other articles, particles having a median particle diameter of larger than 60 microns may be preferred. Included among the various types of abrasive materials useful in the present invention are particles of aluminum oxide including ceramic aluminum oxide, heat-treated aluminum oxide and white-fused aluminum oxide; as well as silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, and combinations of the foregoing. Useful abrasive particles may also include softer, less aggressive materials such as thermosetting or thermoplastic polymer particles as well as crushed natural products such as nut shells, for example.
Those skilled in the art will appreciate that the selection of particle composition and particle size will depend on the contemplated end use of the finished abrasive article, taking into account the nature of the workpiece surface to be treated by the article and the abrasive effect desired. Preferably, the fine abrasive particles for inclusion in the articles of the invention comprise materials having a Moh's hardness of at least about 5, although softer particles may be suitable in some applications, and the invention is not to be construed as limited to particles having any particular hardness value. Preferably, in the manufacture of hand pads for use in the foregoing automotive applications, the fine abrasive particles comprise aluminum oxide particles having the foregoing distribution of particle sizes. The particles are added to at least one of the first or second major surfaces of the nonwoven web to provide a particle loading which is adequate for the contemplated end use of the finished article. in the preparation of articles for the aforementioned automotive application, for example, the fine abrasive particles may be applied to the web to provide an add-on weight preferably within the range of from about 63 to 168 grams/m2 (about 15 to 40 grains per 24 in2) per each side of the web.
After applying fine abrasive particles 102 to at least the first surface 104 of web 100, and optionally to second surface 106, the web 100 is preferably exposed to a heat source (not illustrated), such as infrared lamps or an oven, to heat the make coat precursor to the extent necessary to at least partially cure the resin. In some applications, it may be preferable to fully cure the make coat precursor at this step. Heating can be done with any source giving sufficient heat distribution and air flow. Examples of suitable heat sources include forced air oven, convection oven, infrared heat, and the like. It is also within the scope of the present invention to use radiation energy. For heat-activatable thermosetting resin foams, it is preferred that heating be for a sufficient amount of time to at least drive off solvent (e.g., water) and initiate at least partial curing (cross-linking) of the resin.
In a preferred embodiment, the web 100 passes through second adhesive or size precursor coater 28 after exiting the second abrasive particle coater 26. Preferably, the size precursor coater is of the same configuration as the make precursor coater 20. For some applications, it may instead be desired to use a coater 28 of a different configuration from that of the first coater 20. In some applications, it may be preferred not to add the size coat.
The make coat precursor or the size coat precursor or both can contain optional additives, such as fillers, fibers, lubricants, grinding aids, wetting agents, surfactants, pigments, dyes, coupling agents, plasticizers, suspending agents, antistatic agents and the like. Possible fillers include calcium carbonate, calcium oxide, calcium metasilicate, alumina trihydrate, cryolite, magnesia, kaolin, quartz, and glass. Fillers that can function as grinding aids include cryolite, potassium fluoroborate, feldspar, and sulfur. Fillers can be used in amounts up to about 400 parts, preferably from about 30 to about 150 parts, per 100 parts of the make or size coat precursor, while retaining good flexibility and toughness of the cured coat. The amounts of these materials are selected to provide the properties desired, as known to those skilled in the art.
A preferred embodiment of first particle coater 22 is illustrated in greater detail in FIG. 3. Web 100 is conveyed through the coater 22 by a carrier belt 30 which passes around rollers 32a and 32b, at least one of which is a drive roller. The web 100 passes through particle spray booth 34. Booth 34 includes first side 36, second side 38, top 40, and bottom 42. Booth 40 also includes front and back sides not illustrated. First side 36 includes entry slot 44a sized and configured to allow web 100 and carrier belt 30 to enter the booth 34. Second side 38 includes exit slot 44b sized and configured to allow web 100 and belt 30 to exit the booth 34. Slots 44a, 44b are located near the bottom of sides 36, 38 respectively. Mounted through an opening in the top 40 of the booth 34 is particle sprayer 46, having deflector 48 mounted at the exit 47 of the sprayer. The web 100, which at this point includes a make coat precursor thereon, is carried by belt 30 through the booth 34. As the web passes from entry slot 44a to exit slot 44b, particle sprayer 46 introduces particles 102 into the booth so as to coat the first side 104 of the web with abrasive particles. As described below, the particles 102 will penetrate to some depth into the web 100. The web 100, now comprising abrasive particles adhered to the web by the make coat precursor, then exits the booth 34.
In one preferred embodiment, the particle sprayer 46 receives an abrasive particle/air mixture from fluidizing bed 52. Abrasive particles 102 are fluidized in the bed 52 by fluidizing air (from a suitable source, not illustrated), introduced into the bed via fluidizing air inlet 53. The fluidizing air flow rate should be high enough to cause fluidization, without being so high so as to cause "worm holes" through the bed, i.e., a small number of discrete locations where the air passes through the particles without causing significant fluidization throughout the bed. The flow rate of fluidizing air also should be selected to minimize "stratification" of the particles 102, i.e., a state in which smaller particles tend to migrate toward the top of the bed while larger particles tend to migrate toward the bottom of the bed.
Atop the fluidizing bed 52 is a venturi inlet 56 as is well known in the art. In the illustrated embodiment, venturi 56 receives primary air from a suitable source via primary air inlet 58. The primary air passes through the venturi 56-drawing the mixture of fluidized particles and air through the draw tube 54 which extends from the venturi 56 into the fluidizing bed 52. Secondary air optionally can be added to the venturi inlet 56 via secondary air inlet 60. The secondary air is added to the flow of fluidized abrasive particles after the particles are drawn into the venturi to aid in delivering the fluidized abrasive particle/air mixture to the sprayer 46 via particle hose 64 which extends from the venturi exit 62 to the inlet of the particle sprayer 46.
The deflector 48 mounted in the exit 47 of the particle sprayer 46 redirects the fluidized abrasive particle/air mixture. Deflector 48 includes deflector top 49 (illustrated in FIGS. 5 and 6), deflector bottom 50, and deflector wall 51. To obtain the preferred uniform distribution of fine abrasive particles on web 100 described above, the present inventors have discovered that it is preferable to redirect the flow of the fluidized abrasive particle/air mixture so as not to spray the mixture directly into the web 100. Instead, the desired uniform distribution of abrasive particles 102 is achieved with the method and apparatus of the present invention by creating a uniformly dispersed cloud of abrasive particles in the spray booth 34 above the web 100 having the liquid make coat precursor thereon. The cloud then deposits, preferably by settling due to gravity, onto the web 100 in the desired uniform pattern. Such a uniformly dispersed cloud helps prevent the individual fine abrasive particles from agglomerating or clumping together. Instead, the abrasive particles settle from the cloud onto the web having the make coat thereon as illustrated in FIG. 4. In one preferred arrangement, the deflector bottom 50 has a diameter of 32 mm (1.26 inches), the bottom edge of the deflector extends 20 mm (0.79 inches) from the exit of the spray gun, and is held at a height of 155 mm (6.1 inches) above the nonwoven web 100. Of course, other arrangements fall within the scope of the present invention. For example, the size of the deflector, the shape of the deflector, the contour of wall 51, the number and location of particle sprayers 46, the height of the deflectors above the web, the speed of the web 100, and the air pressure and ratio of abrasive particles in the particle/air mixture can each be varied. Such parameters can be varied to achieve the desired add-on weight of abrasive particles, the desired penetration into the web 100 of the abrasive particles, and the desired uniformity of the abrasive particles 102 on the web 100.
In one preferred embodiment, sprayer 46, fluidizing bed 52, and controller (not illustrated) is a commercially available system known as MPS 1-L Manual Powder System, including model PG 1-E Manual Enamel Powder Gun, available from Gema, an Illinois Tool Works Company, of Indianapolis, Ind., with a round deflector 48 substantially as illustrated in FIG. 3.
In another preferred embodiment, the abrasive particle spray apparatus is of the type commercially available from Binks Manufacturing Company (Sames), of Franklin Park, Ill. and includes a 50 lb. Fluidized bed, a GCM-200 Gun Control Module, a SCM-100 Safety control Module, a STAJET SRV Type 414 gun, with a standard powder pump.
Another preferred embodiment of particle sprayer 46 is illustrated in FIGS. 5 and 6. In this embodiment, the sprayer comprises an elongate tube 66 having an exit 47 at one end and an inlet 68 at the opposite end of the tube. In use, this embodiment of the sprayer 46 has the abrasive particle/air mixture hose 64 attached to the inlet 68 as is illustrated with respect to the earlier described embodiment of FIG. 3. The embodiment of the sprayer 46 illustrated in FIGS. 5 and 6 is mounted in spray booth 34 and operates as described with respect to the embodiment of particle coater 22 illustrated in FIG. 3.
Returning to FIGS. 5 and 6, sprayer 46 includes particle deflector 48 mounted at exit 47 of tube 66. Deflector 48 is mounted to the tube 66 by any suitable mounting means. In one preferred embodiment, deflector mount 70 includes a base 72 comprising a generally rectangular plate having a first end 74 and a second end 76. Base 72 is sized and configured to fit in slot 69 in the end of tube 66 proximate the exit 47. Mount 70 can be permanently or removably mounted to the tube 66. In the illustrated embodiment, base 72 is releasably held in slots 69 by a spring, clip, or other suitable fastener (not illustrated) affixed to holes 78 in the first and second ends of base 72. Extending from base 72 is a threaded rod 80 having a first end 82 affixed to the base (such as by brazing, for example) and second end 84 extending beyond the exit 47 of tube 66. Threaded rod 82 is configured to engage with a like-threaded hole in the top 49 of deflector 48. This allows the position of deflector 48 to be conveniently adjusted with respect to the exit 47 of the tube 66 by rotating the deflector 48. This allows for varying the direction of motion of the particles 102 leaving the sprayer 46 as described above. Deflector 48 also includes bottom 50 opposite top 49, and deflector wall 51 extending between top 49 and bottom 50.
Another preferred embodiment of the abrasive particle sprayer 46 is illustrated in FIG. 7. In this embodiment, the sprayer 46 comprises rotating first and second circular discs 90 and 91, respectively, joined by studs 93. Second disc 91 has a hole 92 in the center thereof. Second disc is joined to rotating shaft 94 which is concentric with the center hole 92. Rotating shaft 94 is rotatably mounted on the outside of stationary feed tube 95 by means of bearings 98, such that rotating shaft 94 is concentric with stationary feed tube 95. In this manner, rotating shaft 94, first plate 90, and second plate 91 are able to rotate together as a unit about stationary feed tube 95. The rotating shaft 94 can be driven by any suitable power means, such as an air motor (not illustrated). Feed tube 95 includes inlet 96 and outlet 97. In one preferred embodiment, inlet 96 of the feed tube 95 is attached to abrasive particle/air mixture hose 64, and the particle sprayer 46 is mounted on the top 40 of particle booth 34 as explained with regard to the embodiment of FIG. 3. In such an arrangement, the particle sprayer 46 receives fluidized abrasive particles from the fluidizing bed 52. In a variation of this, embodiment, a vibratory feeder can be used in place of the fluidizing bed 52. The vibratory feeder is connected to feed abrasive particles into the inlet 96 of feed tube 95.
In operation, the rotating shaft 94 is driven so as to cause plates 90 and 91 to rotate. Abrasive particles pass through feed tube 95 and exit from outlet 97. Tube outlet 97 is positioned through hole 92 in second plate 91 such that the abrasive particles enter the space between first and second plates 90, 91. The abrasive particles strike the top surface of rotating plate 90, and will be dispersed through exit 47 in a direction generally parallel to the plane of first and second plates 90, 91. The particles preferably form a cloud that deposits, preferably by settling due to gravity, onto the surface of web 100 as explained with regard to the embodiments described above. In one preferred embodiment, particle sprayer 46 comprises a Binks EPB-2000, commercially available from Binks Manufacturing Company (Sames), of Franklin Park, Ill., and the abrasive particles are fed to the particle sprayer by a vibratory pre-feeder commercially available as "Type 151" from Cleveland Vibratory Company, Cleveland, Ohio. The plates 90, 91 of the particle sprayer are preferably driven at 6,000 to 9000 RPM, however slower and faster speeds are within the scope of the present invention. The abrasive particle feed rate, type of particle feeder, and rotational speed of the plates can be selected to provide the desired abrasive particle spray pattern, desired abrasive particle add-on weight, and desired degree of penetration into web 100 of the abrasive particles.
What is common to the preferred embodiments described herein is that the particle sprayer includes means to change the direction of flow of particles 102 exiting the sprayer from perpendicular to the web 100, to a direction approaching, or exceeding, a plane parallel to web 100. Such directions are described with reference to the area immediately surrounding the exit 47 of particle sprayer 46. Thereafter, the particles 102 preferably disperse into a cloud of particles in the booth 34. The particles then settle from the cloud onto the web under the influences of gravity. Thus in one preferred embodiment of the inventive method, immediately before the particles adhere to web 100, gravity has a greater effect on the motion of the abrasive particles than does the momentum imparted by the particle sprayer 46. In some applications, the momentum imparted by the particle sprayer 46 will have little or no effect on the motion of the particles 102 immediately before the particles adhere to web 100. In other applications, for example where greater penetration of abrasive particles 102 into the web 100 is desired, the above apparatus parameters and configuration may be selected such that the downward momentum imparted to the particles 102 by the sprayer 46 will have a greater effect on the motion of the particles immediately before the particles adhere to the web.
In the embodiments described with respect to FIGS. 3, 5, and 6, the means for directing the flow of particles 102 exiting the particle sprayer 46 is the deflector wall 51 of deflector 48. Preferably, the location of the deflector 48 relative to the exit 47 of the particle sprayer can be varied to obtain the desired redirection of flow of abrasive particles 102 exiting the particle sprayer. It will be appreciated that without the deflector 48, the abrasive particles exiting the particle sprayer 46 will travel generally parallel to the longitudinal axis of the sprayer, which is generally perpendicular to the web 100. Generally, the closer the wall 51 and bottom 50 of the deflector are to the exit 47, the greater change in direction of motion of particles 102 from perpendicular to the web 100 will be. Moving the wall 51 and bottom 50 of the deflector further from the exit 47 will reduce the amount the direction of motion of the particles is varied from perpendicular to the web 100. In the embodiment described with respect to FIG. 7, the means for directing the flow of abrasive particles is the rotating plates 90, 91.
For some applications, it is preferable to use a plurality of particle sprayers 46 in a single spray booth 34. Preferably, each of the particle sprayers are of like configuration, however it is understood that different types of particle sprayers could be used in a single booth. The particle sprayers 46 should be arranged in a pattern that provides a uniform coating of abrasive particles 102 to the web 100 as the web passes through the booth 34. This can be accomplished by arranging the plurality of particle sprayers 46 such that each location across the width of the web 100 from first edge 107 to second edge 108 traverses through an equal number of spray patterns 45 caused by each of the particle sprayers 46. Exemplary particle sprayer arrangements are illustrated schematically in FIGS. 8A through 8D. These figures are schematic top views of the web 100 passing under the spray patterns 45 created by particle sprayers 46 mounted in the top 40 of the booth 34 (not shown). It is possible to vary the flow rates of each of the plurality of sprayers 46, or to use different configurations of sprayers 46 to obtain a desired coating pattern of abrasive particles 102 on web 100. It is also possible to oscillate or reciprocate the particle sprayers 46 to achieve a desired spray pattern as is known in the art.
When using a plurality of particle sprayers 46, it is possible to use a like number of particle coaters 22 as illustrated in FIG. 3, where each particle sprayer receives abrasive particles 102 for a respective fluidizing bed 52. In some applications, it is preferable to feed a plurality of particle sprayers 46 from a single fluidizing bed 50. In one such arrangement, a plurality of venturi injectors 56 are mounted on a single fluidizing bed. In an alternate arrangement, a plurality of volumetric control auger feeders are mounted on the side wall of a fluidizing bed to draw a desired rate of fluidized abrasive particle/air mixture from the fluidizing bed 50. The operation and design of such feeders is well known and need not be further discussed. Each auger feeder deposits the abrasive particles into a venturi injector 56 as described above. Each venturi injector 56 is connected to an abrasive particle/air mixture hose 64 for conveying the abrasive particle/air mixture to a particle sprayer 46 as described above. In one preferred embodiment, the fluidizing bed 50 having a plurality of auger feeders mounted thereon is of the type commercially available as the "Powder Delivery Control Unit" Gema, an Illinois Tool Works Company, of Indianapolis, Ind. It is also within the scope of the invention to feed abrasive particles from a volumetric feeder of the type commercially available as Dry Material Feeder from AccuRate of Whitewater, Wis.
It is also within the scope of the present invention to include additional particle sprayers configured to spray abrasive particles onto the web 100 with enough force to achieve greater penetration into the center portion of the web. Such additional particle sprayers can be included in the spray booth 34 along with the particle sprayers 46 described above, either in the arrangement of particle sprayers 46, or arranged to spray the web 100 before or after the web passes under sprayers 46. Such additional sprayers could also be arranged in a second particle spray booth before or after the sprayers 22, 26, described above. Preferably, the additional sprayers are arranged to deposit abrasive particles onto the web before the sprayers 46, so as not to disturb or disrupt the advantageous spray pattern achieved by the sprayers 46. Such a combination of sprayers can be used to provide a web 100 having the advantageous fine particle distribution at surfaces 104, 106 as described herein, along with particles in the center portion of the web for a longer-life abrasive article.
In one preferred embodiment, the web 100 has a width from first edge 107 to second edge 108 of 61 cm (24 inches) and is fed through apparatus 14 at a web speed of from about 3 to 30 meters/minute (10 to 100 feet/minute), more preferably about 16 meters/minute (52.5 feet/minute). The first adhesive coater 20 is a double roll coater with the web 100 passing through the nip formed by the two opposed rollers. The foamed make coat precursor is applied to the top roller from a frother through a slot die as is known in the art. In one preferred embodiment, the frother is of the type commercially available as a "F2S-8" from SKG Industries, West Lawn, Pa. The make coat precursor preferably comprises a thermoset phenolic resin, frothed with a blow ratio of about 10:1, in an amount to achieve a dry add-on weight of approximately 34 to 84 grams/M2 (approximately 8 to 20 grains per 24 inch2), and more preferably about 63 grams/M2 (approximately 15 grains per 24 inch2). The abrasive particles 102 are applied by eight particle sprayers 46 generally as described with respect to FIGS. 5 and 6, fed by eight venturi injectors 56 mounted on a fluidizing bed 52. The spray pattern of the injectors is generally as illustrated with respect to FIG. 8C. The abrasive particles 102 preferably comprise aluminum oxide particles having a median particle size of about 60 microns, applied to each side in an amount of from about 63 to 168 grams/m2 (about 15 to 40 grains per 24 inch2), more preferably in an amount of about 105 grams/m2 per side (25 grains per 24 inch2). The make coat precursor is then partially cured. The second adhesive coater 26 preferably is of the same type as the first adhesive coater 20. The size coat precursor preferably has the same composition as the make coat precursor, is frothed to a desired blow ratio as mentioned above, and is applied in an amount to provide a suitable dry add-on weight. The parameters for the Gema particle coater described above are as follows: fluidizing air introduced through inlet 53 at a pressure of from about 2 to 15 psi; primary air introduced into inlet 58 of venturi 56 at a pressure of up to 90 psi, preferably 30 to 60 psi; secondary air introduced into inlet 60 at a pressure of from 0 to about 90 psi, preferably from 0 to about 20 psi.
The methods and apparatuses described herein provide the advantageous abrasive article as illustrated in FIG. 4. By applying the foamed make coat precursor in the manner described herein, the tendency for the make coat precursor to migrate or concentrate and agglomerate is reduced. The provides fibers of the web 100 which are more uniformly coated with the make coat precursor, allowing the abrasive particles to be coated onto and adhered to the web in a more uniform distribution. And by coating the make coat precursor and abrasive particles in different steps, the abrasive particles are less likely to be "buried" within the make coat as is prone to happen in the prior art method of applying a make coat precursor/abrasive particle slurry. In the finished articles made by the methods and appratuses of the invention, the size coat provides a light coating of resin over the fine abrasive particles without burying the particles within the resin. When observed under a microscope, for example, the individual particles are observed to be anchored to the fibers and to extend outwardly from the outer surfaces of the fibers. In this construction, the fine abrasive particles are positioned in the article to be immediately abrasively effective in the initial applications of the finished article. Moreover, the particles are strongly adhered to the fibers of the web to provide an abrasive article with a satisfactory work life.
The operation of the present invention will be further described with regard to the following detailed examples. These examples are offered to further illustrate the various specific and preferred embodiments and techniques. It should be understood, however, that many variations and modifications may be made while remaining within the scope of the present invention. Unless otherwise indicated, all parts and percentages are by weight.
A scuffing test was used to simulate the abrasive qualities of abrasive articles on typical automotive painted surfaces. The test specimens are prepared from poly(methyl) methacrylate sheet material 1/8 inch (3.2 mm) thick, Rockwell Ball Hardness of 90-105, available in 48×96-inch (1.22×2.44 m) sheets under the trade name "Acrylite" from American Cyanamid, Wayne, N.J. Following the removal of the protective covering from the top side of the acrylic sheet, a double coat of "PPG Black Universal Base Coat" paint (PPG Industries Inc., Automotive Finishes Division, Cleveland, Ohio) was applied per the manufacturer's recommendations. The black base coat was painted over with three (3) double coats of "PPG Paint DAU-82, Clear" (PPG Industries Inc., Automotive Finishes Division, Cleveland, Ohio) per the manufacturer's recommendations, allowing about 30 minutes of "flash time" between each double coat application. The coated sheets were allowed to air-dry for approximately 72 hours. A number of 4-inch (10.2 cm) diameter test specimens were cut from the coated sheet with care taken to minimize the scratching of the painted surface. The cut discs were then baked at 150° F. (66° C.) in an oven, avoiding any contact with the coated surface, for about 16 hours to fully cure the paint coatings. The test specimens were then ready for testing.
The tests were conducted on a Schiefer Abrasion Machine (available from Frazier Precision Company, Gaithersburg, Md.) fitted with a spring clip retaining plate to secure the painted test specimen on the bottom turntable and a mechanical fastener (3M SCOTCHMATE DUAL LOCK SJ3442 Type 170) to hold the abrasive composition on the upper turntable. For each test, the counter was set to run 500 revolutions. A 4-inch (10.2 cm) diameter disc of the abrasive article to be tested was cut and mounted on the upper turntable via the mechanical fastener. In the event that the abrasive article had contact surfaces significantly different from each other, notation was made as to which side was being tested. A previously-prepared 4-inch (10.2 cm) diameter painted acrylic disc was weighed to the nearest milligram (W1) and mounted via the-spring clip to the lower turntable with the painted surface facing up. A 10 lb (4.55 kg) weight was placed on the load platform of the abrasion tester. If the abrasion tester is plumbed for wet testing, the water supply is shut off The upper turntable was lowered to contact the painted acrylic disc under the full force of the load weight, and the machine was started. After 500 revolutions, the machine was turned off, the abrasive article removed from the upper turntable and discarded, and the painted acrylic disc was removed from the lower turntable. Any free dust or detritus was removed from the painted acrylic disc by wiping with a dry paper towel and the disc weighed again (W2). The difference W1 -W2 is reported to the nearest milligram as "cut".
Abrasive Particles: is ANSI grade 280 and finer Al2 O3 particles having a median particle diameter of about 28 microns.
A lofty, random air-laid fabric was formed on a "Rando Webber" machine (Rando Machine Corporation, Macedon, N.Y.) consisting of 147 g/m2 of 12 denier×38 mm Nylon Staple Fibers. The web was approximately 61 cm (24 inches) wide. A prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 109 g/m2. The prebond was then cured in an oven at 170° C. for 105 seconds. A make coat precursor having the composition set forth in Table 1 was frothed using a frother (commercially available under the trade designation "F2S-8" from SKG Industries, West Lawn, Pa.) as per the manufacturer's recommended procedure with a blow ratio of about 17:1. The frothed make coating was delivered to the top roll of a two-roll coater via a slot die, whereby the frothed make coat precursor was applied to the previously-coated and cured prebonded web to provide a make coat dry add-on weight of 63 g/m2. Abrasive Particles were applied to the uncured make coat precursor at an add-on weight of 105 g/m2 to each side of the froth-coated web via a particle sprayer (commercially available under the trade designation "Sames EPB 2000", Binks Manufacturing company, Franklin Park, Ill.) operated at approximately 9,000 RPM. The Abrasive Particles were drop fed into the particle sprayer without feed air from a vibratory pre-feeder (commercially available under the trade designation "Type 151", Cleveland Vibratory Company, Cleveland, Ohio). The exit of the particle sprayer was set at a sufficient height above the surface of the web to deposit the abrasive particles across the entire surface of the web. The web was passed underneath the sprayer at a web speed of approximately 7.6 meters/minute (25 feet/minute). The abrasive-coated web was then cured in an oven at 148° C. for 72 seconds followed by further heating at 160° C. for 72 seconds. A size coat precursor of the composition shown in Table 1 was frothed at a blow ratio of about 17:1 and applied in the same manner as the make coat precursor to provide a dry size coat add-on weight of 92 g/m2, and the size coat precursor was subjected to a final cure in an oven at 148° C. for 72 seconds followed by heating at 160° C. for 72 seconds. Test specimens were evaluated according to the Scuffing Test procedure. The results are summarized in Table 2.
Example 2 was made according to the procedure and materials used in Example 1 with the following exceptions: 1) the compositions used as the prebond, make coat and size coat precursors are set forth as "Example 2" in Table 1; 2) the make coat precursor dry add-on weight was 50 g/m2 ; 3) the size coat precursor dry add-on weight was 63 g/m2 ; 4) Abrasive Particles were applied to only one side of the web with an add on weight of 105 g/m2, applied by four particle sprayers of the type illustrated in FIG. 6A which were positioned generally as illustrated with respect to FIG. 8D at a height of 155 mm above the web. The particle sprayers were fed by four venturi injectors 56 mounted on a fluidizing bed 52 as described with respect to the embodiment illustrated in FIG. 3. The parameters for the particle coater were as follows: fluidizing air introduced through inlet 53 at a pressure of about 5 psi; primary air introduced into inlet 58 of venturi 56 at a pressure of about 60 psi; no secondary air introduced into inlet 60, the 61 cm (24 inches) wide web was fed at a web speed of 15.4 meters/minute (50 feet/minute); 5) the make coat precursor was cured at only the 148° C. temperature for 72 seconds; and 6) the size coat precursor composition was cured at 148° C. for 432 seconds. Test specimens were tested according to the Scuffing Test, and the results are summarized in Table 2.
Comparative Example A is a commercially-available nonwoven abrasive surface conditioning material having the trade designation "SCOTCH-BRITE 07447 A-VFN General Purpose Hand Pad" available from the Minnesota Mining and Manufacturing Company of St. Paul, Minn.: The pad comprises a nonwoven substrate having a fiber weight of about 147 g/m2, a total resin weight of about 250 g/m2 and a mineral loading of about 210 g/m2. The mineral used in this pad is aluminum oxide of grade 280 and finer having a median particle diameter of about 28 microns. Comparative Example A was tested according to the Scuffing Test procedure, and the results are summarized in Table 2.
TABLE 1______________________________________Coating CompositionsCoating  Component    Example 1 Example 2______________________________________Prebond  Phenolic Resin                 73.2   parts                             73.2   parts    water        20     parts                             20     parts    Red Dye Mix  6      parts                             6      parts    Antifoam     0.015  parts                             0.015  partsMake     Phenolic Resin                 62     parts                             60     parts    water        31     parts                             33     parts    Surfactant   3      parts                             3      parts    Red Dye Mix  4      parts                             3      partsSize     Phenolic Resin                 62     parts                             60     parts    water        31     parts                             33     parts    Surfactant   3      parts                             3      parts    Red Dye Mix  4      parts                             3      parts______________________________________
TABLE 2______________________________________Scuffing Test  Initial weight,             Final weight,                        Cut, grams                                Average Cut,Example  grams      grams      removed grams______________________________________1      27.186     26.889     0.2971      27.048     26.730     0.318   0.3082      27.333     27.034     0.2992      27.449     27.124     0.3252      27.598     27.297     0.301   0.308Comp. A  25.807     25.724     0.083Comp. A  27.088     26.999     0.089Comp. A  25.807     25.724     0.083Comp. A  27.088     26.999     0.089   0.086______________________________________
The articles made by the methods and apparatuses of the present invention can be used to abrade and/or polish a wide range of workpiece surfaces. These workpiece surfaces include metal (including mild steel, carbon steel, stainless steel, gray cast iron, titanium, aluminum and the like), metal alloys (copper, brass and the like), exotic metal alloys, ceramics, glass, wood (including pine, oak, maple elm, walnut, hickory, mahogany, cherry and the like), wood like materials (including particle board, plywood, veneers and the like) composites, painted surface, plastics (including thermoplastics and reinforced thermoplastics), stones (including jewelry, marble, granite, and semi precious stones), glass surfaces including glass television screens, windows (including home windows, office windows, car windows, air windows, train windows, bus windows and the like); glass display shelves, mirrors and the like) and the like. The abrasive article may also be used to clean surfaces such as household items (including dishes, pots, pans and the like), furniture, walls, sinks, bathtubs, showers, floors and the like.
The workpiece may be flat or may have a shape or contour associated with it. Examples of specific workpieces include ophthalmic lenses, glass television screens, metal engine components (including cam shafts, crankshafts, engine blocks and the like), hand tools metal forgings, fiber optic polishing, caskets, furniture, wood cabinets, turbine blades, painted automotive components, bath tubs, showers, sinks, and the like.
Depending upon the particular application, the force at the abrading interface an range from about 0.01 kg to over 100 kg, typically between 0.1 to 10 kg. Also depending upon the application, there may be a polishing liquid present at the interface between the abrasive article and the workpiece. This liquid can be water and/or an organic solvent. The polishing liquid may further comprise additives such as lubricants, oils, emulsified organic compounds, cutting fluids, soaps and the like. The abrasive article may oscillate at the polishing interface during use.
The abrasive article made by the methods and apparatuses of the invention can be used by hand or used in combination with a machine. For example, the abrasive article may be secured to a random orbital tool or a rotary tool. At least one or both of the abrasive article and the workpiece is moved relative to the other.
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ClassificationB24D13/14, B24D11/00, B24D3/28Cooperative ClassificationB24D13/147, B24D3/28European ClassificationB24D3/28, B24D13/14DLegal EventsDateCodeEventDescriptionNov 12, 1997ASAssignmentOwner name: MINNESOTA MINING AND MANUFACTURING COMPANY, MINNESFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BEARDSLEY, KRIS A.;LISE, JONATHAN M.;NICCUM, BRENT D.;AND OTHERS;REEL/FRAME:008942/0670;SIGNING DATES FROM 19971111 TO 19971112Sep 13, 1999ASAssignmentOwner name: 3M INNOVATIVE PROPERTIES COMPANY, MINNESOTAFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MINNESOTA MINING AND MANUFACTURING COMPANY;REEL/FRAME:010216/0967Effective date: 19990827Jul 25, 2002FPAYFee paymentYear of fee payment: 4Aug 13, 2002REMIMaintenance fee reminder mailedJul 26, 2006FPAYFee paymentYear of fee payment: 8Jun 28, 2010FPAYFee paymentYear of fee payment: 12RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send 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