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Abrasive articles comprising precisely shaped particles    
United States Patent5500273   
Link to this pagehttp://www.wikipatents.com/5500273.html
Inventor(s)Holmes; Gary L. (Vadnais Heights, MN); Culler; Scott R. (Burnsville, MN); Hardy; David H. (New Richmond, WI); Hendrickson; William A. (St. Joseph, WI); Klun; Thomas P. (Lakeland, MN); Harmon; Kimberly K. (Hudson, WI); Heiti; Robert V. (Hudson, WI); Spurgeon; Kathryn M. (River Falls, WI); Studiner, III; Charles J. (Oakdale, MN)
AbstractAbrasive articles comprising precisely shaped particles are disclosed. The particles are bonded together to form a shaped mass, e.g., a wheel; alternatively, the particles can be bonded to a backing to form a coated abrasive article; or the particles can be bonded into a fibrous, nonwoven substrate to form a non-woven abrasive article.
   














 Title Information Submit all comments and votes
 
Patent Text Patent PDF Print Page Summary File History
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Inventor     Holmes; Gary L. (Vadnais Heights, MN); Culler; Scott R. (Burnsville, MN); Hardy; David H. (New Richmond, WI); Hendrickson; William A. (St. Joseph, WI); Klun; Thomas P. (Lakeland, MN); Harmon; Kimberly K. (Hudson, WI); Heiti; Robert V. (Hudson, WI); Spurgeon; Kathryn M. (River Falls, WI); Studiner, III; Charles J. (Oakdale, MN)
Owner/Assignee     Minnesota Mining and Manufacturing Company (St. Paul, MN)
Patent assignment
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Publication Date     March 19, 1996
Application Number     08/445,364
PAIR File History     Application Data   Transaction History
Image File Wrapper   Patent Term   Fees
Litigation
Filing Date     May 19, 1995
US Classification     428/147 51/295 51/298 51/309 442/58
Int'l Classification     D06N 007/04
Examiner     Raimund; Christopher W.
Assistant Examiner    
Attorney/Law Firm     Griswold; Gary L. Kirn; Walter N. , Busse; Paul W. ,
Address
Parent Case     This is a continuation of application Ser. No. 08/085,638 filed Jun. 30, 1993, pending.
Priority Data    
USPTO Field of Search     428/147 428/283 428/290 51/295 51/298 51/309
Patent Tags     abrasive articles comprising precisely shaped particles
   
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What is claimed is:

1. An abrasive article comprising a plurality of precisely shaped composites and a bonding medium wherein said precisely shaped composites comprise

(a) a plurality of abrasive grits and

(b) a polymeric binder, said binder formed by exposing a free radically polymerizable binder precursor to radiation energy,

wherein said precisely shaped composites are bonded together by means of said bonding medium to form a shaped mass or wherein said precisely shaped composites are distibuted within a non-woven web and bonded to the web fibers by means of said bonding medium.

2. An abrasive article according to claim 1, wherein said abrasive grits are selected from the group consisting of fused aluminum oxide, ceramic aluminum oxide, heat treated aluminum oxide, silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, and combinations thereof.

3. An abrasive article according to claim 1, wherein the size of said precisely shaped composites ranges from about 0.1 to about 2500 micrometers.

4. An abrasive article according to claim 1, wherein the size of said precisely shaped composites ranges from about 0.1 to about 500 micrometers.

5. An abrasive article according to claim 1, wherein said precisely shaped composites have shapes selected from the group consisting of pyramids, cones, prisms, spheres, and ellipsoids.

6. An abrasive article according to claim 1, wherein said precisely shaped composites are triangular-based pyramids.

7. An abrasive article according to claim 1, wherein said precisely shaped composites are quadrilateral-based pyramids.

8. An abrasive article according to claim 1, wherein said binder precursor is selected from the group consisting of acrylated urethane resins, acrylated epoxy resins, ethylenically unsaturated resins, aminoplast resins having pendant unsaturated carbonyl groups, isocyanurate derivatives having at least one pendant acrylate group and isocyanate derivatives having at least one pendant acrylate group.

9. An abrasive article according to claim 1, wherein said binder precursor further comprises a free radical initiator.

10. An abrasive article according to claim 1, wherein said precisely shaped composites further comprise at least one additive selected from the group consisting of fillers, grinding aids, fibers, antistatic agents, lubricants, wetting agents, surfactants, pigments, dyes, coupling agents, plasticizers, and suspending agents.

11. An abrasive article according to claim 1, wherein said precisely shaped composites comprise from 5 to 95% by weight abrasive grits and from 95 to 5% by weight binder.

12. An abrasive article according to claim 1, wherein said precisely shaped composites comprise from 20 to 75% by weight abrasive grits and from 80 to 25% by weight binder.

13. An abrasive article according to claim 1, wherein said bonding medium comprises a resinous adhesive.

14. An abrasive article according to claim 13, wherein said resinous adhesive is selected from the group consisting of phenolic resins, epoxy resins, urea-formaldehyde resins, acrylate resins, acrylated epoxy resins, acrylated urethane resins, aminoplast resins having pendant alpha, beta unsaturated carbonyl groups, maleimide resins, and urethane resins.

15. An abrasive article according to claim 1, further comprising individual abrasive grits.
 Description Submit all comments and votes
 


BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to particulate material comprising a binder, and a method for making same. When the particulate material further contains abrasive grits, it can be used in bonded abrasives, coated abrasives, and nonwoven abrasives.

2. Discussion of the Art

Conventional coated abrasive articles typically consist of a layer of abrasive grits adhered to a backing. Generally only a small fraction of the abrasive grits in this layer are actually utilized during the useful life of the coated abrasive article. A large proportion of the abrasive grits in this layer are wasted. Furthermore, the backing, one of the more expensive components of the coated abrasive article, must also be disposed of before it has worn out.

Many attempts have been made to distribute the abrasive grits on the backing in such a manner so that a higher percentage of abrasive grits are actually utilized, thereby extending the useful life of the coated abrasive article. By extending the life of the coated abrasive article, fewer belt or disc changes are required, thereby saving time and reducing labor costs. Merely depositing a thick layer of abrasive grits on the backing will not solve the problem, because grits lying below the topmost grits are not likely to be used.

Several methods whereby abrasive grits can be distributed in a coated abrasive article in such a way as to prolong the life of the article are known. One such way involves incorporating abrasive agglomerates in the coated abrasive article. Abrasive agglomerates consist of abrasive grits bonded together by means of a binder to form a mass. The use of abrasive agglomerates having random shapes and sizes makes it difficult to predictably control the quantity of abrasive grits that come into contact with the surface of a workpiece. For this reason, it would be desirable to have an economical way to prepare precisely shaped abrasive agglomerates.

SUMMARY OF THE INVENTION

This invention provides precisely shaped particles and methods for making these particles. The particles comprise a binder. In one desirable embodiment, a plurality of abrasive grits is dispersed in the binder.

The method of this invention comprises the steps of:

(a) providing a production tool having a three-dimensional body which has at least one continuous surface, said surface containing at least one opening formed in said continuous surface, said at