KR20160071416A - Coated abrasive article and method of making the same - Google Patents

Abstract

The structured abrasive article is contacted by a laser beam to create a microporous surface area on a portion of the abrasive surface to produce a coated abrasive article comprising an abrasive layer comprising a backing and a polishing composite secured to the backing.

Description

[0001] COATED ABRASIVE ARTICLE AND METHOD OF MAKING THE SAME [0002]

This disclosure relates generally to coated abrasive articles and methods of making the same.

The coated abrasive article generally comprises an abrasive layer secured to a backing. The backing typically has two major surfaces on opposite sides of the backing. The abrasive layer generally comprises abrasive particles held by at least one binder matrix. In a particular type of coated abrasive article (also known as a "structured abrasive article"), the abrasive layer comprises a plurality of shaped abrasive composites. Each shaped abrasive composite (e.g., a pyramid) comprises abrasive particles retained within the binder matrix.

In many structured abrasive articles, the shaped abrasive composite has a distinct geometric shape, such as a three-face pyramid or a cut pyramid, or a four-face or six-face post. This type of structured abrasive article is commercially available for example from the 3M Company (St. Paul, MN, USA) under the trade name "TRIZACT" for several years. Such structured abrasive articles typically include casting a slurry of abrasive particles and a curable binder matrix precursor into a cavity of a production tool and then laminating the backing to the mold surface of the manufacturing tool, Curing the matrix precursor, and separating the manufacturing tool from the resulting structured abrasive article. The abrasive composites produced by this process have typically been referred to as being "precision-shaped", having a smooth surface when viewed at high magnification due to the fact that it was molded prior to curing. As a result, a break in period is typically required before the optimum grinding performance is achieved, as the abrasive particles are buried in the binder matrix and the initial cut rate is lowered.

In one method described in U.S. Patent No. 8,444,458 (Culler et al.), An abrasive article, such as a structured abrasive article, can be treated by applying it to a plasma, whereby the abrasive surface is eroded to form a cross- At least a portion of the abrasive particles dispersed in the abrasive particles may be exposed to form the abrasive composite. Depending on the processing conditions for the plasma treatment, it is possible to erode only a small portion of the cross-linked binder from the polishing surface or substantially all of it. The initial cutting rate of the abrasive article can be controlled because it is possible to precisely control the degree, height or area of the abrasive particles to be exposed.

However, plasma etching is a relatively complex, costly process and is generally best suited for uniform (i.e., unmasked) exposure when implemented on a roll article. There is a need for an alternative method for controlling the initial cut rate.

The present disclosure provides an alternative method of affecting the rate of cut of a structured abrasive article. The method may conveniently be performed during manufacture, during conversion, and after conversion using generally available laser equipment, and the method is generally applicable to structured abrasive articles.

In one aspect, the present disclosure provides a method of making a coated abrasive article,

A backing having a first major surface and an opposing second major surface; And

The abrasive layer-abrasive layer affixed to the first major surface of the backing comprises a abrasive composite secured to a first major surface of the backing, the abrasive layer having a polishing surface opposite the second major surface of the backing, Providing a structured abrasive article comprising abrasive particles held in a binder matrix, wherein the abrasive surface has a first projecting region on a first major surface of the backing; And

Wherein at least one microporous surface zone-most of the microporous surface zone on the polishing surface comprises a binder matrix, wherein at least one microporous surface zone is in contact with at least one microporous surface zone Wherein the projection of at least one microporous surface zone on the first major surface in a direction perpendicular to the first major surface has a greater surface roughness than a portion of the abrading surface immediately adjacent to the first major surface And the ratio of the second protruding area to the first protruding area is 0.15 to 0.90 (inclusive of these values).

In yet another aspect,

A backing having a first major surface and an opposing second major surface; And

A polishing abrasive article comprising a polishing layer secured to a first major surface of a backing, the polishing layer comprising abrasive composite anchored to a first major surface of the backing, The protrusion of the polishing surface on the first major surface in a direction perpendicular to the first major surface corresponds to a first protruding area on the first major surface of the backing and the abrasive composite has an abrasive surface on the opposite side of the abrasive surface, Particles,

Wherein the polishing surface comprises at least one microporous surface region, wherein the majority of the microporous surface region comprises a binder matrix, and wherein at least one microporous surface region comprises at least one microporous surface region in a portion of the polishing surface immediately adjacent to the at least one microporous surface region Wherein the projection of at least one microporous surface area on the first major surface in a direction perpendicular to the first major surface has a second projected area on the first major surface of the backing, The ratio of the second protruding region to the region is 0.15 to 0.90 (inclusive).

The resulting laser-treated coated abrasive article produced in accordance with this disclosure is useful, for example, for polishing workpieces and may exhibit improved initial cuts compared to unmodified forms of the same abrasive article.

As used herein, "close-packed " in the context of a shaped abrasive composite refers to the base (or the base) of each shaped (e.g., pyramidal or truncated pyramidal) (Or openings of respective corresponding cavities in the manufacturing tool used) are adjacent to the shaped shaped abrasive composites (or cavities) along their entire circumference, but of course the circumference of the abrasive layer or mold that is not possible is excluded.

As used herein, the term "laser-treated " in connection with shaped abrasive composites is used to describe a portion of a shaped abrasive composite (e.g., by vaporization or in the case of abrasive particles, ) And a laser beam of sufficient intensity and duration.

As used herein, the term "microporous surface zone" refers to a surface zone having dense holes and / or gaps of about 0.5 to 20 micrometers in size.

As used herein, a "precisely-shaped abrasive composite" is formed from a polishing slurry present in a cavity in a mold that is at least partially cured prior to removal from the mold. Unlike rotogravure printing or embossing methods for making shaped abrasive composites, the molding / partial curing process has significantly better shape retention and edge descriptiveness and is at least partially cured during its existence in the mold A shaped abrasive composite is produced having a surface or shape substantially simulating the surface of the mold. Shaped abrasive composites having shape defects due to manufacturing errors (e.g., including air bubbles) are also encompassed by these terms.

The features and advantages of the present disclosure will be further understood upon consideration of the detailed description of the invention as well as the appended claims.

IA is a schematic perspective view of an exemplary coated abrasive article 100 in accordance with the present disclosure;
Figure 1b is an enlarged view of zone 1b of Figure 1a;
1C is a cross-sectional view of coated abrasive article 100 according to planes 1c-1c;
1D is an enlarged view of Zone 1d of FIG. 1A showing how to calculate the projected area of the polishing surface and its roughened portion; FIG.
Figure 2 is a micrograph at 50X magnification of the coated abrasive article of Example 2;
Figure 3 is a micrograph at 50X magnification of the coated abrasive article of Example 5;
Figure 4 is a micrograph at 50X magnification of the coated abrasive article of Example 13;
5 is a micrograph at 100X magnification of the coated abrasive article of Example 15;
Figure 6 is a micrograph at 50X magnification of the coated abrasive article of Example 18;
Figure 7 is a micrograph at 300X magnification of the coated abrasive article of Example 20;
8 is a micrograph at 1000X magnification of the coated abrasive article of Example 20;
9 is a micrograph at 1500X magnification of the coated abrasive article of Example 20. FIG.
Repeated use of the reference numerals in the present specification and drawings is intended to represent the same or similar features or elements of the present disclosure. It should be understood that many other modifications and embodiments belonging to the scope and spirit of the principles of the present disclosure may be developed by those skilled in the art. The drawings may not be drawn to scale.

This disclosure is directed to a method of improving the initial cutting characteristics of a structured abrasive article that can be easily performed without requiring reformulation of the abrasive article. Briefly, the inventors have found that substantially improved initial cutting (increased material removal) can be achieved by laser processing a substantial portion of the surface of the structured abrasive article.

According to the present method, the laser beam is guided to the abrasive surface of the structured abrasive article with sufficient time and intensity that the abrasive layer is modified. Typically, the energy density of the laser beam should be sufficient to vaporize and / or vaporize the binder matrix or to cause melt flow of the binder matrix. This, in turn, results in the loss of abrasive particles that are no longer tightly bound by the binder matrix. Typically, the method involves material loss (i.e., material removal) at the polishing surface and corresponding weight loss of the structured polishing article.

Suitable lasers include, for example, infrared lasers, visible lasers and ultraviolet lasers. The laser may be an adjustable wavelength or a fixed wavelength and / or a pulsed wave or a continuous wave (CW). Examples of the infrared laser having a sufficient output include carbon dioxide (CO ₂₎ laser. Other lasers operating in the infrared wavelength range include, for example, solid state determination lasers (e.g., ruby, Nd / YAG), chemical lasers, carbon monoxide lasers, fiber lasers, and solid state laser diodes. Typically, pulsed infrared lasers (including ultra-high speed pulsed lasers) are very efficient because they deliver higher peak irradiance than continuous wave infrared lasers of generally equivalent average power to be. CO ₂ lasers are the second most inexpensive infrared laser source next to diode lasers and are substantially cheaper than ultraviolet laser alternatives.

In order to provide rapid processing, the infrared laser beam (s) used in the practice of this disclosure typically have at least 60 watts (W); For example, an average power of 70 W, 80 W, 90 W, or more. Likewise, the cross-sectional area (i.e., spot size) of the infrared laser beam in the substrate to be cut is preferably very small. For example, the infrared laser beam may be such that all portions of the spot having an intensity at least one-half of the average beam intensity have an area less than 0.3 square millimeters (mm 2), less than about 0.1 mm 2, or even less than 0.01 mm 2 (When an infrared laser beam is contacted with a coated abrasive article), but a smaller spot size and a larger spot size may also be used. Using the above conditions, it is possible to achieve good surface roughening so that a trace rate of at least 10 millimeters per second (mm / sec), or even at least 20 mm per second (i.e. the rate at which the beam is scanned across the substrate ), It is typically possible to produce microporous zones, but slower tracer rates may also be used.

The laser processing of the abrasive layer can be accomplished using a single trace of the laser beam or multiple overlapping traces. A plurality of laser beams can be used simultaneously or sequentially. When multiple laser beams are used, they may have the same or different wavelengths. In one embodiment, the individual components of the coated abrasive article are sequentially removed using an infrared laser beam, each adjusted to the absorption band of each component (e.g., backing and polishing layer). In another embodiment, the individual components of the coated abrasive article are simultaneously removed using a plurality of infrared laser beams adjusted to the absorption bands of the separate components of the coated abrasive article (e.g., backing and polishing layer).

For example, if additional components are present, additional infrared lasers may also be used. Where multiple infrared laser beams are used, their traces typically have to be superimposed to achieve maximum benefit, but this is not a requirement.

Absorption of the laser beam by the abrasive layer may include single photon or multiphoton absorption (i.e., nonlinear absorption). Typically, the absorption is a single photon absorption.

Although not required, it is desirable that the backing supporting the structured abrasive layer does not absorb much of the laser beam in order to minimize damage to the backing. This may be accomplished, for example, by laser selection, backing selection, inclusion of the absorbent (s) in the binder matrix, or combinations thereof.

The laser beam is typically optically guided or scanned and adjusted to form the desired pattern for the microporous zone (s). The laser beam may be guided through one or more mirrors (e.g., a rotating mirror and / or a scanning mirror) and / or a combination of lenses. Alternatively or additionally, the substrate may be moved relative to the laser beam. In yet another configuration, the focusing member may move relative to the web (e.g., in one or more of the X, Y, Z alpha, or theta directions). The laser beam can be scanned at an incident angle to the surface of the polishing layer (e.g., the top surface). For example, the angle of incidence may be 90 degrees (i.e., perpendicular to the abrasive layer), 85, 83, 80, 70, 60, 50, 45, or even less.

Although optimal laser operating conditions for manufacturing coated abrasive articles in accordance with the present disclosure may vary depending upon the selected structured abrasive article (e.g., the amount of mineral loading and absorption at the laser frequency typically can vary) It can be easily determined for a given irradiation pattern by adjusting the laser beam intensity and / or the moving speed.

In order to provide long life and to prevent damage to the backing, the laser treatment conditions are preferably adjusted to provide an approximately minimum amount of energy to produce the microporous surface area (s) on the polishing surface. For example, the height reduction of the abrasive composite may be less than 30%, preferably less than 20%, more preferably less than 10%, but this is not a requirement.

The lasers used to switch the abrasive article are preferred in some embodiments because the laser processing step can be performed in such a case at the same time.

An exemplary coated abrasive article is shown in Figs. 1A-1D. Referring now to Figures 1A-1C, a coated abrasive disc 100 has a backing 110 having a first major surface 115 and a second major surface 115, respectively. An optional adhesive layer 120 contacts the second major surface 117 and is attached thereto to be coextensive with it. The structured abrasive layer 130 has an outer boundary 150 and contacts the first major surface 115 of the backing 110 and is attached thereto and flush with it. The structured abrasive layer 130 includes a dense array of pyramidal abrasive composites 162.

An optional attachment interface layer 140 (shown as the loop portion of a hook and loop two-part fastening system) is attached to the second major surface 117 or, if present, Layer 120 as shown in FIG. The microporous surface area 184 of the polishing surface 180 forms a uniformly extended grating pattern 190 on the polishing surface 180. Referring now to FIG. 1C, the pyramidal abrasive composite 162 includes abrasive particles 137 held within a binder matrix 138. A portion of the abrasive surface 180 of the structured abrasive layer 130 includes a laser-treated precisely-shaped abrasive composite material 164.

Referring again to FIG. 1A, the microporous surface area 184 of the abrasive surface 180 of the structured abrasive layer 130 includes a laser-treated precisely-shaped abrasive composite material 164.

7 to 9 and 1C, most of the microporous surface area 184 includes a binder matrix 138 and abrasive particles 137 are relatively less present. In addition, the microporous surface area 184 has a greater surface roughness than the portion 187 of the polishing surface 180 immediately adjacent to the microporous surface area 184.

Figure 1d describes a procedure for protruding the abrasive surface and the microporous surface area on the first major surface of the backing. The polishing surface 180 has a first length 200, a first width 210, and a first height 250, as shown in FIG. The projection in the direction 142 perpendicular to the first major surface 115 reduces the height to zero to create the first projecting surface area 132p. The first protrusion length 200p and the first protrusion width 210p are not changed from the first length 200 and the first width 210, respectively. Then, the first projecting surface area can be calculated as a first length (200) x first width (210). Similarly, for a microporous surface region 184 having a second length 205, a second width 220, and a second height 240, the height is reduced to zero to form a second projecting surface region 134p Which has a second protruding length 205p which is equivalent to the second length 205 and a second protruding width 220p which is equal to the second width 220. [ As described above, in the protruding region, the first length 200 and the first width 220 are not changed after protruding on the first main surface.

Although the example shown in Figure ID illustrates a simple case to facilitate understanding, for example, by analyzing complex patterns and designs in smaller portions and combining the results, the same method can also be applied to complex patterns and designs .

In the case of typical structured abrasive articles, a simple way to measure projected areas is to image the abrasive layer along an observation line perpendicular to the first surface of the backing (e.g., using a digital camera or digital microscope) . Now, the generated two-dimensional image allows direct measurement of both projected surface areas, for example, by pixel analysis or cutting and weighting techniques. In the case of a polishing backing that is not plate-like or can not be made in a plate, it can be repeatedly imaged along a locally vertical line of observation at multiple points on the polishing surface.

The inventors have found that insufficient coverage of the polishing surface by the microporous surface area does not particularly advantageously improve the initial cut. On the other hand, excessive coating of the abrasive surface excessively reduces product life. Therefore, the ratio of the second protruding area to the first protruding area should be in the range of 0.15 to 0.90 (including these values). In some embodiments, the ratio of the second projected area to the first projected area should be in the range of 0.15, 0.20, 0.25, 0.30, 0.35, or even 0.40 to 0.80 (inclusive). In some embodiments, the ratio of the second projected area to the first projected area is in the range of 0.20, 0.25, 0.30, 0.35, or even 0.40 to 0.70 (inclusive). In some embodiments, the ratio of the second projected area to the first projected area is in the range of 0.20, 0.25, 0.30, 0.35, or even 0.40 to 0.60 (inclusive).

The microporous surface zone (s) may be continuous or discontinuous. For example, they may be displayed as a continuous network of intersecting lines (for example, see FIG. 2) or as a parallel network (see, for example, FIG. Or may include an array of discrete microporous surface areas that are visible (e.g., see FIG. 4) or appear as a curved microporous surface zone or a combination thereof. A combination of small microporous surface zone (s) and large microporous surface zone (s) may be used. Likewise, a combination of differently shaped microporous surface zone (s) may also be used.

Preferably, the microporous surface area (s) are arranged on the polishing surface such that they / they extend substantially uniformly throughout the entire polishing surface, in order to ensure uniform polishing characteristics of the coated abrasive article For example,

Structured abrasive articles suitable for conversion to coated abrasive articles using laser-treatment in accordance with the present disclosure are well known and are available in a variety of ways. Examples include those available under the trade designation "TRIZACT" from 3M Company, St. Paul, Minn., USA, for example. A suitable structured abrasive article typically has a structured abrasive layer that is secured to the major surface of the two-dimensional backing. As used herein, the term "structured abrasive layer " refers to an abrasive layer comprising a plurality of shaped abrasive composites each comprising a binder matrix having a plurality of abrasive grains. The shaped abrasive composites on the backing may be randomly positioned or may be arranged in a repeating pattern. The shaped abrasive composite may be different in shape, size, height, spatial density, or other physical properties on the backing.

Several methods can be used to form a structured abrasive layer. In one method, a polishing slurry comprising a cross-linkable binder matrix precursor and abrasive particles can be printed on a backing using a rotogravure coater to form a plurality of shaped abrasive composites. In yet another method, a polishing slurry comprising a cross-linkable binder matrix precursor and abrasive particles is deposited on the backing and subsequently embossed to form a coating layer on the backing; US 5,863,306 (Wei et al.); 5,833,724 (Way et al.); And 6,451,076 (Nevoret et al.), Which are incorporated herein by reference in their entirety. In yet another method, a polishing slurry comprising a cross-linkable binder matrix precursor and abrasive particles is deposited in a mold having a plurality of cavities in opposite phases to the desired pattern, and at least partially curing the cross- U.S. Patent No. 5,152,917 (Pieper et al.); 5,304, 223 (piper et al.); 5,378,251 (cooler, etc.); And No. 5,437,754 (Calhoun et al.), Which are incorporated herein by reference in their entirety.

Suitable backings for structured abrasive articles (and thus coated abrasive articles produced after laser processing) include, for example, polymer films (including primed polymer films), fabrics, paper, Nonwoven webs, non-porous polymeric foams, vulcanized fibers, fiber-reinforced thermoplastic backings, meltspun or meltblown nonwovens, treated versions thereof (e.g., waterproofing), and combinations thereof. Suitable thermoplastic polymers for use in polymeric films include, for example, polyolefins (e.g., polyethylene and polypropylene), polyesters (e.g., polyethylene terephthalate), polyamides (e.g., nylon-6 and nylon- , Polyimides, polycarbonates, blends thereof, and combinations thereof.

Typically, at least one major surface of the backing is flat (e.g., to serve as the first major surface). The second major surface of the backing may comprise a non-slip coating or a friction coating. Examples of such coatings include inorganic microparticles (e.g., calcium carbonate or quartz) dispersed in an adhesive.

The backing may include various additive (s). Examples of suitable additives include colorants, processing aids, reinforcing fibers, heat stabilizers, UV stabilizers and antioxidants. Examples of useful fillers include clay, calcium carbonate, glass beads, talc, clay, mica, wood powder and carbon black. In some embodiments, the backing may be a composite film, such as a coextruded film having, for example, two or more separate layers.

The structured abrasive layer may have an abrasive composite (e.g., forming an array) arranged in a dense array, which can form an abscissa abrasive zone. The structured abrasive layer may have pyramidal abrasive composites arranged in a tight array to form a sweep abrasive zone. The raised abrasive regions are typically shaped and arranged identically on the backing according to the repeating pattern, none of which is a necessary condition.

The term "pyramidal shaped abrasive composite" refers to a pyramid, i.e., a polishing compound having a polygonal bottom surface and a shape of a three-dimensional figure having triangular surfaces meeting at a shared point (apex). Examples of suitable types of pyramid shapes include 3-sided, 4-sided, 5-sided, 6-sided pyramids, and combinations thereof. The pyramid may be regular (i. E., All sides are the same) or irregular. The height of the pyramid is the minimum distance from the vertex to the bottom.

The term truncated pyramidal shaped abrasive composite refers to abrasive composites having a truncated pyramid, that is, a shape of a truncated pyramid having a polygonal base and triangular faces meeting at a shared point, the vertices of which are cut away and replaced with a plane parallel to the base. Examples of types of suitable truncated pyramid shapes include 3-sided, 4-sided, 5-sided, 6-sided truncated pyramids, and combinations thereof. The truncated pyramid may be regular (i. E., All sides are the same) or irregular.

For fine finishing applications, the height of the pyramidal shaped abrasive composites (i.e., not cut) is generally greater than 1 mil (25.4 micrometers) to less than 20 mils (510 micrometers); For example, less than 15 mils (380 micrometers), 10 mils (250 micrometers), 5 mils (130 micrometers), 2 mils (50 micrometers), but larger or smaller heights may also be used.

In one embodiment, the structured abrasive layer 130 forms a continuous network consisting essentially of a dense cut pyramidal abrasive composite that continuously contacts and separates the abrasive abrasive zones from each other. As used herein, the term "successively adjacent " means that in a compact array of, for example, truncated pyramidal shaped abrasive composites and pyramidal shaped abrasive composites, the network is proximate to each of the raised abrasive portions. The network may be formed along a straight line, a curve or a line segment thereof, or a combination thereof. Typically, the network extends throughout the structured abrasive layer, and more typically the network has a regular arrangement (e.g., a network of intersecting parallel lines or hexagonal patterns). In some embodiments, the network has a minimum width that is at least twice the height of the pyramidal shaped abrasive composite.

In this embodiment, the ratio of the height of the truncated pyramidal abrasive composite to the height of the pyramidal abrasive composite is less than 1, typically at least 0.05, 0.1, 0.15 or even 0.20 to 0.25, 0.30, 0.35, 0.40, 0.45, 0.5 Or even less than 0.8, other ratios may be used. More typically, the ratio ranges from at least 0.20 to less than 0.35.

For fine finishing applications, the areal density of the pyramidal and / or truncated pyramidal shaped abrasive composites within the structured abrasive layer is typically at least 1,000, 10,000, or even at least 20,000 abrasive composites per square inch (e.g., Ranges from 50,000, 70,000, or even 100,000 abrasive composites (7,800, 11,000 or even 15,000 abrasive composites per square centimeter or less) per square inch from at least 150, 1500, or even 7,800 abrasive composites per square centimeter Larger or smaller abrasive composite densities can also be used.

The ratio of the pyramid-shaped base ratios to the truncated pyramid-shaped base, i.e., the summed area of the base of the pyramidal-shaped abrasive composite relative to the combined area of the base of the truncated pyramidal shaped abrasive composite, is determined by the cutting and / or finishing of the structured abrasive article It can affect performance. For fine finishing applications, the pyramidal bottom aspect ratio to the truncated pyramidal bottom surface is typically in the range of 0.8 to 9, such as 1 to 8, 1.2 to 7, or 1.2 to 2, Can be used.

The individual shaped abrasive composites (whether pyramidal, truncated, pyramidal or otherwise) comprise abrasive grains dispersed in a crosslink-bonded polymeric binder. Any abrasive grains known in the abrasive art may be included in the abrasive composite. Examples of useful abrasive grains include aluminum oxide, fused aluminum oxide, heat treated aluminum oxide (including brown aluminum oxide, heat treated aluminum oxide, and white aluminum oxide), ceramic aluminum oxide, silicon carbide, green silicon carbide, alumina-zirconia Chromia, ceria, iron oxide, garnet, diamond, cubic boron nitride, and combinations thereof. For repair and finishing applications, useful abrasive grain sizes typically have an average particle size of at least 0.01, 0.1, 1, 3 or even 5 micrometers to 35, 50, 100, 250, 500, or even 1,500 micrometers Although particle sizes outside this range may also be used. Abrasive grains are described, for example, in U.S. Patent No. 4,311,489 (Kressner); And U.S. Patent Nos. 4,652,275 and 4,799,939, both of which are described in Bloecher et al., (Without binder) to form a mass.

The abrasive grains may be surface treated thereon. In some cases, the surface treatment may increase adhesion to the binder, alter the abrasive properties of the abrasive particles, or otherwise. Examples of surface treatments include coupling agents, halide salts, metal oxides including silica, refractory metal nitrides, and refractory metal carbides.

The shaped abrasive composite (whether pyramidal, truncated, pyramidal or otherwise) may typically comprise diluent particles of the same order of magnitude as the abrasive particles. Examples of such diluent particles include gypsum, marble, limestone, flint, silica, glass bubbles, glass beads, and aluminum silicates.

The abrasive particles are dispersed in the binder matrix to form a shaped abrasive composite. Typically, the binder matrix includes organic polymeric binders and optional additives such as grinding aids and / or filler particles, lubricants, surfactants, coating aids, and initiators (including residual heat and / or photoinitiators). The binder matrix may be thermoplastic; It is typically thermosetting. The crosslinking-bonded binder is formed from the binder matrix precursor. During the manufacture of the structured abrasive article, the thermosetting binder matrix precursor is exposed to an energy source that aids in initiating the polymerization or curing process to crosslink the binder matrix. Examples of energy sources include thermal energy and radiation energy including electron beams, ultraviolet light and visible light.

After such a polymerization process, the binder matrix precursor is converted to a solidified cross-linked material.

Alternatively, in the case of a crosslinkable thermoplastic binder matrix precursor, during manufacture of the structured abrasive article, the thermoplastic binder matrix precursor may be cooled to such an extent that it leads to the solidification of the binder matrix precursor. Once the binder matrix precursor is solidified, a polishing composite is formed.

There are two major thermosetting resins that can be used in the binder matrix precursor, namely condensation curable resins and addition polymerizable resins. The addition polymerizable resin is advantageous because it is easily cured by exposure to radiation energy. The addition polymerizable resin can be polymerized via a cationic mechanism or a free radical mechanism. Depending on the chemistry of the energy source and binder matrix precursor used, curing agents, initiators, or catalysts are sometimes desirable to aid in initiating polymerization.

Examples of typical binder matrix precursors are phenolic resins, urea-formaldehyde resins, aminoplast resins, urethane resins, melamine formaldehyde resins, cyanate resins, isocyanurate resins, acrylate resins (e.g., acrylated Urethane, acrylated epoxy, ethylenically unsaturated compound, pendant alpha, an aminoplast derivative having a beta-unsaturated carbonyl group, an isocyanurate derivative having at least one pendant acrylate group, and an isocyanurate derivative having at least one pendant acrylate group Isocyanate derivatives), vinyl ethers, epoxy resins, and combinations and mixtures thereof. The term acrylate includes acrylate and methacrylate. In some embodiments, the binder is selected from the group consisting of acrylic, phenol, epoxy, urethane, cyanate, isocyanurate, aminoplast, and combinations thereof.

Phenolic resins are suitable for this disclosure and have good thermal properties, availability, and relatively low cost and ease of handling. There are two types of phenolic resins, resole and novolac. The resol phenol resin has a molar ratio of formaldehyde to phenol of at least 1: 1, typically from 1.5: 1.0 to 3.0: 1.0. The novolac resin has a molar ratio of formaldehyde to phenol of less than 1: 1. Examples of commercially available phenolic resins are commercially available from Occidental Chemicals Corp. (Dallas, Texas, USA) under the trade designations DUREZ and VARCUM, Monsanto K.K. From "Monsanto Co." (St. Louis, Missouri, USA) to "RESINOX" and from Ashland Specialty Chemical Co. (Dublin, OH) AEROFENE "and" AROTAP ".

The acrylated urethane is a diacrylate ester of NCO extended polyester or polyether of the hydroxy end type. Examples of commercially available acrylated urethanes are available from Morton International of Chicago, Ill. Under the trade designation "UVITHANE 782 "; CMD 8400 " and "CMD 8805" from Cytec Industries of West Patterson, NJ.

The acrylated epoxies are diacrylate esters of epoxy resins, such as the diacrylate esters of bisphenol A epoxy resins. Examples of commercially available acrylated epoxies include those available under the trade designations "CMD 3500 "," CMD 3600 ", and "CMD 3700 " from UCB Inc. of Smyrna, .

Ethylenically unsaturated resins include both monomeric and polymeric compounds containing carbon, hydrogen and oxygen atoms and optionally nitrogen and halogen. Oxygen or nitrogen atoms, or both, are generally present in the ether, ester, urethane, amide, and urea groups. The ethylenically unsaturated compound preferably has a molecular weight of less than about 4,000 g / mole, preferably an aliphatic monohydroxy group or an aliphatic polyhydroxy group and an unsaturated carboxylic acid such as acrylic acid, methacrylic acid, Acetic acid, crotonic acid, isocrotonic acid, maleic acid, and the like. Representative examples of acrylate resins are methyl methacrylate, ethyl methacrylate, styrene, divinyl benzene, vinyl toluene, ethylene glycol diacrylate, ethylene glycol methacrylate, hexane diol diacrylate, triethylene glycol diacryl Trimethylol propane triacrylate, glycerol triacrylate, pentaerythritol triacrylate, pentaerythritol methacrylate, pentaerythritol tetraacrylate, and pentaerythritol tetraacrylate. Other ethylenically unsaturated resins include monoallyl, polyallyl, and polymethallyl esters and amides of carboxylic acids, such as diallyl phthalate, diallyl adipate, and N, N-diallyl adipamide. Other nitrogen-containing compounds include tris (2-acryloyloxyethyl) isocyanurate, 1,3,5-tri (2-methyacryloxyethyl) -s-triazine, acrylamide, methyl acrylamide, N-methyl acrylamide, N, N-dimethylacrylamide, N-vinylpyrrolidone, and N-vinylpiperidone.

The aminoplast resin has at least one pendant alpha, beta-unsaturated carbonyl group per molecule or oligomer. These unsaturated carbonyl groups may be acrylate, methacrylate or acrylamide type groups. Examples of such materials are N- (hydroxymethyl) acrylamide, N, N'-oxydimethylenebisacrylamide, ortho- and para-acrylamidomethylated phenols, acrylamidomethylated phenol novolacs, And combinations thereof. Such materials are further described in U.S. Patent Nos. 4,903,440 and 5,236,472, both to Kirk et al.

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. Patent No. 4,652,274 (Boettcher et al.). An example of an isocyanurate material is the triacrylate of tris (hydroxyethyl) isocyanurate.

The epoxy resin has oxirane and is polymerized by ring opening. Such epoxide resins include monomeric epoxy resins and oligomeric epoxy resins. Examples of useful epoxy resins are 2,2-bis [4- (2,3-epoxypropoxy) phenylpropane] (diglycidyl ether of bisphenol) and Momentive (Columbus, (EPON) 828, Epon 1004, and Epon EPON 1001F; And DER-331, DER-323, and DER-334 from Dow Chemical Co., Midland, Mich., USA. Other suitable epoxy resins include glycidyl ethers of phenol formaldehyde novolak commercially available as DEN (DEN) -431 and DEN-428 from Dow Chemical Co.

The epoxy resin of the present disclosure can be polymerized via a cationic mechanism using the addition of a suitable cationic curing agent. The cationic curing agent initiates the polymerization of the epoxy resin by generating an acid source. These cationic curing agents may comprise a salt having an onium cation and a halide-containing complex anion of a metal or metalloid.

Other cationic curing agents include salts with organometallic complex cations and halide-containing complex anions of metals or metalloids, which are further described in U.S. Patent No. 4,751,138 (Tumey et al.). Another example is an organometallic salt, and onium salts are described in U.S. Patent No. 4,985,340 (Palazzotto et al.); 5,086,086 (Brown-Wensley et al.); And 5,376, 428 (Palazzo et al.). Another cationic curing agent comprises an ionic salt of an organometallic complex, wherein the metal is selected from Group IVB, VB, VIB, VIIB and VIIIB elements of the Periodic Table, as described in U.S. Patent 5,385,954 (Palazzo et al) .

With respect to free radical curable resins, in some cases it is preferred that the polishing slurry further comprises a free radical curing agent. However, in the case of an electron beam energy source, a curing agent is not always required because the electron beam itself generates free radicals.

Examples of free radical thermal initiators include peroxides, such as benzoyl peroxide, azo compounds, benzophenones, and quinones. In the case of ultraviolet or visible light sources, such curing agents are sometimes referred to as photoinitiators. Examples of initiators that generate free radical sources when exposed to ultraviolet light include organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acryl halides, hydrozones, mercapto compounds, pyrylium compounds, But are not limited to, sols, bisimidazoles, chloroalkytriazines, benzoin ethers, benzyl ketals, thioxanthones, and acetophenone derivatives, and mixtures thereof. An example of an initiator that generates a free radical source when exposed to visible light is found in US 4,735,632 (Oxman et al). One initiator suitable for use with visible light is available from " IRGACURE 369 " from Ciba Specialty Chemicals (Terrytown, NY).

An abrasive article having a structured abrasive layer is formed by forming a slurry of abrasive grains and the solidified and polymeric precursor (i. E., The binder matrix precursor) of the above-mentioned binder resin, contacting the slurry with the backing, Or by polymerizing and / or polymerizing the binder matrix precursor in such a manner that the article has a plurality of shaped abrasive composites attached to the backing (e.g., by exposure to an energy source). Examples of energy sources include thermal energy and radiation energy (including electron beams, ultraviolet light, infrared light and visible light).

The polishing slurry is formed by combining the binder matrix precursor, abrasive grains, and optional additives together by any suitable mixing technique. Examples of mixing techniques include low shear and high shear mixing, and high shear mixing is preferred. Ultrasonic energy may also be used with the mixing step to lower the polishing slurry viscosity. Typically, the abrasive particles are gradually added to the binder matrix precursor. The amount of bubbles in the polishing slurry can be minimized by introducing a vacuum during or after the mixing step. In some cases, it is useful to lower the viscosity by heating the polishing slurry in the range of generally 30 to 70 占 폚.

For example, in one embodiment, the slurry may be coated directly on the manufacturing tool having a cavity (corresponding to the desired structured abrasive layer) shaped therein to contact the backing, or may be coated on the backing, . ≪ / RTI > Typically, the slurry is then solidified (e.g., at least partially cured) or cured while it is in the cavity of the manufacturing tool, and the backing is separated from the tool to form an abrasive article having a structured abrasive layer.

In one embodiment, the surface of the manufacturing tool is comprised of a pyramidal cavity (e.g., a three-sided pyramidal cavity, a four-sided pyramidal cavity, a five-sided pyramidal cavity, a six-sided pyramidal cavity, And a truncated pyramidal cavity (e.g., a truncated pyramidal cavity, a four-faceted truncated pyramidal cavity, a five-faceted truncated pyramidal cavity, a six-truncated pyramidal cavity, and combinations thereof) ≪ RTI ID = 0.0 > a < / RTI > dense array of cavities. In some embodiments, the ratio of the depth of the truncated pyramidal cavity to the depth of the pyramidal cavity is in the range of 0.2 to 0.35. In some embodiments, the depth of the pyramidal cavity is in the range of 1 to 10 micrometers. In some embodiments, the pyramidal cavity and the truncated pyramidal cavity each have an areal density of at least 150 cavities per square centimeter.

The manufacturing tool can be a belt, a sheet, a continuous sheet or web, a coating roll such as a rotogravure roll, a sleeve mounted on a coating roll, or a die. The manufacturing tool may comprise a metal (e.g., nickel), a metal alloy, or plastic. The metal manufacturing tool may be manufactured by any conventional technique such as, for example, engraving, bobbing, electroforming, or diamond turning.

The thermoplastic tool can be replicated from the metal master tool. The master tool will have the reverse phase pattern required for the manufacturing tool. The master tool can be manufactured in the same manner as the manufacturing tool. The master tool is preferably made of metal, for example nickel, and diamond-turned. The thermoplastic sheet material can optionally be heated together with the master tool, and by pressing the two together, the thermoplastic material is embossed with the master tool pattern. The thermoplastic material can also be extruded or cast into the master tool and then pressed. The thermoplastic material is cooled to solidify to produce a manufacturing tool. Examples of preferred thermoplastic manufacturing tool materials include polyester, polycarbonate, polyvinyl chloride, polypropylene, polyethylene, and combinations thereof. If a thermoplastic manufacturing tool is used, care must be taken not to generate excessive heat that can distort the thermoplastic manufacturing tool.

The manufacturing tool may also include a release coating to facilitate easier release of the abrasive article from the manufacturing tool. Examples of such release coatings for metals include light carbide, nitride or boride coatings. Examples of release coatings for thermoplastics include silicones and fluorochemicals.

Additional details regarding structured abrasive articles having precisely shaped abrasive composites, and methods of making the same are described, for example, in U.S. Patent No. 5,152,917 (Fippers et al.); U.S. Patent No. 5,435,816 (Spurgeon et al.); U.S. Patent No. 5,672,097 (Hoopman); U.S. Patent No. 5,681,217 (Hoffman et al.); U.S. Patent No. 5,454,844 (Hibbard et al.); U.S. Patent No. 5,851,247 (Stoetzel et al.); And U.S. Patent No. 6,139,594 (Kincaid et al).

In another embodiment, a slurry comprising a polymerizable binder matrix precursor, abrasive grains, and a silane coupling agent is deposited on the backing in a patterned manner (e.g., by screen or gravure printing) Partially polymerizing the surface of the coated slurry so that at least the surface of the coated slurry is plastic but not flowing and the pattern is embossed when the partially polymerized slurry is prepared and then further polymerized (e.g., by exposure to an energy source To form a plurality of shaped abrasive composites attached to the backing. Such embossed abrasive articles having structured abrasive layers produced by such methods and related methods are described in U.S. Patent No. 5,833,724 (Wei et al.); 5,863, 306 (Way et al.); 5,908, 476 (Nishio et al.); 6,048, 375 (Yang et al.); 6,293, 980 (Way et al.); And U.S. Patent Application Publication No. 2001/0041511 (Lack et al.).

The back side of the abrasive article may be printed with appropriate information according to conventional practice, for example, to indicate information such as product identification number, grade number, and / or manufacturer. Alternatively, the front of the backing may be printed with this same type of information. When the abrasive composite is translucent enough to read the print through the abrasive composite, the entire surface can be printed.

A coated abrasive article according to the present disclosure may include an attachment interface layer attached to a second major surface of the backing to facilitate securing the abrasive article to a support pad or backup pad that is secured to a tool such as a random tracked sander, . ≪ / RTI > The optional adhesive interface layer may be a layer of adhesive (e. G., Pressure sensitive adhesive) or a double-sided adhesive tape. The optional attachment interface layer may be adapted to work with one or more complementary elements attached to the support pads or backup pads to function properly. For example, the optional attachment interface layer may be a loop fabric for a hook-and-loop attachment (e.g., for use in a backup or support pad with a hooked structure), a hook- (E.g., for use in backup or support pads with looped fabric attached thereto), or intermeshing attached interface layers (e.g., similar mushroom-shaped fastening fasteners on backup pads or support pads) A mushroom-shaped interlock fastener designed to engage. Additional details regarding such attachment interface layers are described, for example, in U.S. Patent No. 4,609,581 (Ott); 5,152,917 (Piper et al.); 5,254,194 (Haute); 5,454, 844 (Hibbard et al.); 5,672,097 (Hoffman); 5,681,217 (Hoffman et al.); And United States Patent Application Publication No. 2003/0143938 (Braunschweig et al.) And 2003/0022604 (Annen et al.).

Likewise, as described, for example, in U.S. Patent No. 5,672,186 (Chesley et al.), The second major surface of the backing may have a plurality of integrally formed hooks protruding from the surface. This hook will then provide a coupling between the structured abrasive article and the backup pads to which the loop fabric is attached.

The structured abrasive article and the resulting coated abrasive article useful in the practice of the present disclosure may be of any shape, e.g., circular (e.g., disk), circular An elliptical shape, a scalloped edge, or a rectangle (e.g., a sheet), or may have the form of an endless belt. The structured abrasive article and / or the resulting coated abrasive article may have slots or slits therein and may have holes (e.g., perforated disks).

Coated abrasive articles according to the present disclosure are generally useful for polishing workpieces, particularly those workpieces having a hard polymer layer. However, the workpiece may include any material and may have any shape. Examples of materials include metals, metal alloys, new metal alloys, ceramics, painted surfaces, plastics, polymer coatings, stone, polycrystalline silicon, wood, marble, and combinations thereof. Examples of workpieces include molded and / or shaped articles (e.g., optical lenses, automotive body panels, hulls, counters and sinks), wafers, sheets, and blocks.

The coated abrasive article according to the present disclosure may have an optional antiloading composition disposed on at least a portion of the abrasive layer. The function of the anti-loading composition is to reduce swarf buildup during polishing. Examples of suitable anti-lock compositions are well known to those skilled in the art of polishing, including, for example, U.S. Patent No. 5,667,542 (Law et al); 5,704,952 (et al.); And 6,261,682 (incorporated herein by reference).

Coated abrasive articles in accordance with the present disclosure are typically useful for repairing and / or polishing polymer coatings such as vehicle coatings and clearcoats (e.g., automotive clearcoats), examples of which include polyacryl- - polyisocyanate compositions (as described, for example, in U.S. Patent No. 5,286,782 (Lamb et al.)); Hydroxyl functional acrylic-polyol-polyisocyanate compositions (as described, for example, in U.S. Patent No. 5,354,797 (Anderson et al.)); Polyisocyanate-carbonate-melamine compositions (as described, for example, in U.S. Patent No. 6,544,593 (Nagata et al.)); And solid high polysiloxane compositions (such as those described in U.S. Patent No. 6,428,898 (Barsotti et al.)).

Depending on the application, the force at the polishing interface may range from about 0.1 kg to more than 1000 kg. Generally, this range is a force of from 1 kg to 500 kg at the polishing interface. Further, depending on the application, a liquid may be present during polishing. Such liquids may be water and / or organic compounds. Examples of typical organic compounds include lubricating oils, oils, emulsified organic compounds, cutting fluids, surfactants (e.g., soaps, organic sulphates, sulfonates, organic phosphonates, organic phosphates), and combinations thereof. These liquids may also contain other additives such as defoamers, degreasing agents, corrosion inhibitors, and combinations thereof.

A coated abrasive article in accordance with the present disclosure may be used, for example, with a rotating tool that rotates along a central axis generally perpendicular to the structured abrasive layer, or with a tool having a random orbit (e.g., a random orbital sander) It can oscillate at the polishing interface during use. In some cases, such vibrations can result in finer surfaces on the workpiece being polished.

Selected embodiments of the present disclosure

In a first embodiment, the present disclosure provides a method of making a coated abrasive article,

A backing having a first major surface and an opposing second major surface; And

The abrasive layer-abrasive layer affixed to the first major surface of the backing comprises a abrasive composite secured to a first major surface of the backing, the abrasive layer having a polishing surface opposite the second major surface of the backing, Providing a structured abrasive article comprising abrasive particles held in a binder matrix, wherein the abrasive surface has a first projecting region on a first major surface of the backing; And

Wherein at least one microporous surface zone-most of the microporous surface zone on the polishing surface comprises a binder matrix, wherein at least one microporous surface zone is in contact with at least one microporous surface zone Wherein the protrusion of at least one microporous surface zone on the first major surface in a direction perpendicular to the first major surface has a second protrusion on the first major surface of the backing, And the ratio of the second protruding area to the first protruding area is 0.15 to 0.90 (inclusive of these values).

In a second embodiment, the present disclosure provides a method of making a coated abrasive article according to the first embodiment wherein the ratio of the second projected area to the first projected area is 0.25 to 0.80, inclusive.

In a third embodiment, the present disclosure provides a method of making a coated abrasive article according to the first embodiment wherein the ratio of the second projecting area to the first projecting area is 0.35 to 0.70, inclusive.

In a fourth embodiment, the present disclosure provides a method of making a coated abrasive article according to any of the first through third embodiments wherein at least one microporous surface region is uniformly disposed on the polishing surface .

In a fifth embodiment, the present disclosure is directed to a coated abrasive article according to any of the first through fourth embodiments, wherein at least one microporous surface region forms a uniformly extended lattice pattern on the abrasive surface. And a manufacturing method thereof.

In a sixth embodiment, the present disclosure provides a method of making a coated abrasive article according to any one of the first through fifth embodiments, wherein at least a portion of the abrasive composite comprises a pyramid.

In a seventh embodiment, the present disclosure provides a method of manufacturing a coated abrasive article according to any of the first through sixth embodiments, wherein the coated abrasive article comprises a coated abrasive disk or a coated abrasive belt do.

In an eighth embodiment,

A backing having a first major surface and an opposing second major surface; And

A polishing abrasive article comprising a polishing layer secured to a first major surface of a backing, the polishing layer comprising abrasive composite anchored to a first major surface of the backing, The protrusion of the polishing surface on the first major surface in a direction perpendicular to the first major surface corresponds to a first protruding area on the first major surface of the backing and the abrasive composite has an abrasive surface on the opposite side of the abrasive surface, Particles,

Wherein the polishing surface comprises at least one microporous surface region, wherein the majority of the microporous surface region comprises a binder matrix, and wherein at least one microporous surface region comprises at least one microporous surface region in a portion of the polishing surface immediately adjacent to the at least one microporous surface region Wherein the projection of at least one microporous surface area on the first major surface in a direction perpendicular to the first major surface has a second projected area on the first major surface of the backing, The ratio of the second protruding region to the region is 0.15 to 0.90 (inclusive).

In a ninth embodiment, the present disclosure provides a coated abrasive article according to the eighth embodiment wherein the ratio of the second projected area to the first projected area is 0.25 to 0.80, inclusive.

In a tenth embodiment, the present disclosure provides a coated abrasive article according to the eighth embodiment wherein the ratio of the second projected area to the first projected area is 0.35 to 0.70, inclusive.

In an eleventh embodiment, the present disclosure provides a coated abrasive article according to any one of the eighth to tenth embodiments, wherein at least one microporous surface region is uniformly disposed on the polishing surface.

In a twelfth embodiment, the present disclosure provides a coated abrasive article according to any one of the eighth to eleventh embodiments, wherein at least one microporous surface region forms a uniformly extended grating pattern on the abrasive surface. to provide.

In a thirteenth embodiment, the present disclosure provides a coated abrasive article according to any one of the eighth to eleventh embodiments, wherein at least a portion of the abrasive composite comprises a pyramid.

In a fourteenth embodiment, the present disclosure provides a coated abrasive article according to any one of the eighth to thirteenth embodiments, wherein the coated abrasive article comprises a coated abrasive disk or a coated abrasive belt.

The objects and advantages of the disclosure are further illustrated by the following non-limiting examples, but the specific materials and amounts thereof as well as other conditions and details recited in these examples are not intended to be limiting It should not be interpreted.

Example

Unless otherwise stated, all parts, percentages, ratios, etc. in the remainder of the examples and specification are by weight.

Test Methods

Scuffing test

A test disk was subjected to a constant downward force of 5-lb (2.3 kg) and a backup pad mounted on a servomotor rotating in random orbital motion (from a 3M Company to a 3PM- (Available as 3M FINESSE-IT ROLOC SANDING PAD) 02345 (1 1/4-inch (3.18 cm) diameter). GEN IV CLEARCOAT from the automotive sealant and Clearcoat (EI du Pont de Nemours and Co., Wilmington, Del., USA) Two 3 inch (7.6 cm) by 8 inch (20.3 cm) pre-weighed aluminum metal panels (ACT Laboratories, Hillsdale, Mich.) Having Fixed on the table. Approximately 0.3 g of distilled water was applied to the test disc, the test disc was rotated at 7400 rpm, and moved against the test panel to polish a 2 inch (5 cm) diameter spot for about 7 seconds. The disk was removed from the test panel, the servo motor was indexed to a new test area, and the test was repeated to polish three spots on each test panel for a total of six spots. To determine the amount of material removed, each test panel was reweighed using an analytical balance.

Offhand abrasion test

Test discs (1.25-inch discs) from 3M Fern-Roth Rock sanding pad 02345 (1 1/4 inch (3.18 cm)) backup pads from 3M Company 3M MINI RANDOM from 3M Company ORBITAL NIB SANDER) (1 1/4 inch x 3/16 inch (3.18 cm x 0.48 cm) orbit). The test items are: DuPont de Nemours and Koh. Clearcoat automotive bodywork panel from ACTIVREBRELOTREZ (Hillsdale, Mich., USA) with Zen IV clearcoat acrylosilane clearcoat from ZEON (Wilmington, Del., USA). The sanders were activated and the test discs were moved against the test panel for about 4 seconds (about 4 to 5 lb force). Subsequently, the sander was moved to a new spot and the procedure was repeated. The test was continued until the disc no longer appropriately scuffed the test panel. For each test disc, the number of "good spots" (uniformly and clearly scarred areas) and the number of "spots with spots" (less spots with less clear spots, The number was counted.

Laser settings

The structured abrasive surfaces of the examples were laser treated using a 400-watt industrial CO ₂ laser (10.6 micrometer wavelength, 0.18 millimeter spot size, 100 microsecond pulse width) operating at various conditions as listed in Table 1. The laser-processing settings used are reported in Table 1 (below).

[Table 1]

Examples 1 to 6 and Comparative Example A

Examples 1 to 6 and Comparative Example A illustrate the effect of this disclosure in automotive paint repair operations. The structured abrasive film was obtained from 3M Company as 3M Trimat Finn-Itt film-466LA, grade A3 (hereinafter "SAA1"). The laser processing output conditions are shown in Table 2.

Settings 1, 2, and 3 resulted in dots across the surface of the structured abrasive film spaced one millimeter apart while settings 4, 5, and 6 resulted in lines across the surface of the structured abrasive film. Setting 3 removed more abrasive material than setting 2, and setting 2 eventually eliminated more than setting 1, because increasing the output increases the depth of material removal from the polishing layer when the others are all the same. Then, a polishing disk having a diameter of 1 1/4 inch (3.18 cm) was cut from the material for testing using the same laser equipment used to modify the polishing surface.

The results of scuffing tests for Examples 1 to 6 and Comparative Example A are reported in Table 2 (below).

[Table 2]

In Table 2, Comparative Example A did not wear or remove significant amounts of material from the test panel. In all cases, the addition of laser treatment increased the amount of cut. For example, comparing Example 2 with Example 3, and comparing Example 5 with Example 6, it can be seen that, after removing a certain amount of material, . A micrograph of Example 2 is shown in FIG. A micrograph of Example 5 is shown in FIG.

Examples 7 to 12 and Comparative Example B

Examples 7 to 12 and Comparative Example B show the polishing uniformity for laser treated disc versus untreated discs.

Except that the structured abrasive film was grade A5 (hereinafter "SAA2") instead of A3, the test panel clearcoat was a carbamate chemical instead of the acrylosilane chemical, and the four test panels were polished Examples 7 to 12 and Comparative Example B were prepared in the same manner as in Example 1 to Example 6 and Comparative Example A,

Thus, Examples 7 to 12 and Comparative Example B were evaluated according to the scuffing test. The results are reported in Table 3 (below).

[Table 3]

In Table 3, the smaller the reduction in the removal rate, the more consistent the removal rate throughout the test procedure. For both the dot and line designs, Example 7 and Example 10, which are the least power laser treated embodiments, have a smaller removal reduction than the example without any laser ablation, while other embodiments have more dramatic Removal reduction. This means that a very mildly laser treated embodiment is more consistent than the non-treated embodiment.

Manufacture of structured abrasive article SAA3

material

[Table 4]

In sequence, 35.61 parts of SR339, 53.83 parts of SR351H, 2.02 parts of DSP, 5.54 parts of A174, and 3.00 parts of PI were combined to produce a premixed structured abrasive article. Then 28.7 parts of premix was combined with 2.9 parts of OX50 and 68.4 parts of WA4000 and the mixture was stirred with a high shear mixer. The resulting slurry was knife coated onto a polypropylene tool having a 3-sided pyramidal cavity at a depth of 63 micrometers adjacent to it at 60 ft / min (18 m / min) to yield about 1.1 g / 24 in ² (71 g / m ² ) Was achieved. The filled tool was contacted with a 3-mil (76-micrometer) polyester film backing having an EAA primer coating and two D-type bulbs operating at 120 watts / cm (Fusion UV Systems , Inc. (Gatorbag, Maryland, USA)). The polypropylene tool was removed from the composition to yield a structured abrasive article designated SAA3.

Example 13 and Example 14, and Comparative Example C and Comparative Example D

Example 13 and Example 14, and Comparative Example C and Comparative Example D were prepared to compare the effect of laser setting 7 on two structured abrasive articles of different compositions. The discs of the examples were tested according to a scuffing test using two panels with a carbamate clearcoat. The test results are shown in Table 5. A micrograph of Example 13 is shown in FIG.

[Table 5]

Example 15 and Example 16, and Comparative Example E and Comparative Example F

Example 15 and Example 16, and Comparative Example E Comparative Example F was prepared to demonstrate the efficacy of this disclosure on SAA3 under two laser treatment conditions. Comparative Example F was a repeat of Comparative Example E. The disks of the examples were tested according to the off-hand test. The test results are reported in Table 6. A micrograph of Example 15 is shown in Fig.

[Table 6]

Examples 17 to 19 and Comparative Example G

Examples 17 to 19 and Comparative Example G were prepared to illustrate the effect of this disclosure on structured abrasive articles when used on alternative substrates. The abrasive discs of Examples 17-19 were treated with a laser-treated TRIMACT HOOKIT FILM DISC 268XA (5 IN (12.7 cm x NH A10) (manufactured by 3M Company ) Structured abrasive film disk, and Comparative Example G was not laser-treated. 3M RANDOM ORBITAL SANDER - ELITE SERIES 28498 (air-driven, non-vacuum, 5 "(12.7 cm) tool diameter, 3/32" (0.24 cm) (3 "HOOKIT LOW PROFILE FINISHING DISC PAD) 77855 (5" (12.7 cm) diameter × 11/16 "(1.75 cm) thick, 5 / 16-24 EXTERNAL THREAD) To test the example disc. The sanders were activated and the test discs were moved against a highly polished water-wet solid CORIAN surface. I noticed and reported the time needed to create visible swabs and generate enough swabs that looked like bubbles. The test results are reported in Table 7. A micrograph of Example 18 is shown in FIG.

[Table 7]

Example 20

Example 20 was fabricated to show the nature of the laser-treated surface of the abrasive article. SAA1 was laser-treated at laser setting 13. Scanning electron micrographs were obtained at 300x, 1000x, and 1500x using a scanning electron microscope. Micrographs are shown in Figures 7, 8 and 9, respectively.

All references, patents, or patent applications cited in this application for patent claims are incorporated herein by reference in their entirety and in a consistent manner. If there is a discrepancy or inconsistency between the part of the reference incorporated and the present application, the information in the above description shall take precedence. The foregoing description, given to enable those skilled in the art to practice the claimed invention, should not be construed as limiting the scope of the present disclosure as defined by the claims and all equivalents thereto.

Claims (14)

A backing having a first major surface and an opposing second major surface; And
The abrasive layer-abrasive layer affixed to the first major surface of the backing comprises a abrasive composite secured to a first major surface of the backing, the abrasive layer having a polishing surface opposite the second major surface of the backing, Providing a structured abrasive article comprising abrasive particles retained within a binder matrix, the abrasive surface having a first projected area on a first major surface of the backing; And
Wherein at least one microporous surface zone-most of the microporous surface zone on the polishing surface comprises a binder matrix, wherein at least one microporous surface zone is in contact with at least one microporous surface zone Wherein the projection of at least one microporous surface zone on the first major surface in a direction perpendicular to the first major surface has a greater surface roughness than a portion of the abrading surface immediately adjacent to the first major surface And the ratio of the second protruding area to the first protruding area is 0.15 to 0.90 (inclusive). ≪ Desc / Clms Page number 13 > The method of claim 1, wherein the ratio of the second protruding area to the first protruding area is 0.25 to 0.80, inclusive. The method of claim 1, wherein the ratio of the second protruding area to the first protruding area is 0.35 to 0.70 (including these values). 4. The method of any one of claims 1 to 3, wherein at least one microporous surface area is uniformly disposed on the polishing surface. The method according to any one of claims 1 to 4, wherein at least one microporous surface region forms a uniformly extended lattice pattern on the polishing surface. 6. The method of any one of claims 1 to 5, wherein at least a portion of the abrasive composite comprises a pyramid. 7. The method according to any one of claims 1 to 6, wherein the coated abrasive article comprises a coated abrasive disc or a coated abrasive belt. A backing having a first major surface and an opposing second major surface; And
A coated abrasive article comprising an abrasive layer affixed to a first major surface of a backing, the abrasive layer comprising abrasive composites anchored to a first major surface of the backing, the abrasive layer being disposed opposite the second major surface of the backing Wherein the protrusion of the polishing surface on the first major surface in a direction perpendicular to the first major surface corresponds to a first protruding area on the first major surface of the backing and the abrasive composite has abrasive particles retained in the binder matrix Including,
Wherein the polishing surface comprises at least one microporous surface region, wherein the majority of the microporous surface region comprises a binder matrix, and wherein at least one microporous surface region comprises at least one microporous surface region in a portion of the polishing surface immediately adjacent to the at least one microporous surface region Wherein the projection of at least one microporous surface area on the first major surface in a direction perpendicular to the first major surface has a second projected area on the first major surface of the backing, And the ratio of the second projected area to the area is 0.15 to 0.90 (including these values). 9. The coated abrasive article of claim 8, wherein the ratio of the second projecting area to the first projecting area is 0.25 to 0.80, inclusive. 9. The coated abrasive article of claim 8, wherein the ratio of the second projecting area to the first projecting area is 0.35 to 0.70, inclusive. 11. A coated abrasive article according to any one of claims 8 to 10, wherein at least one microporous surface area is uniformly disposed on the polishing surface. 12. The coated abrasive article of any one of claims 8 to 11, wherein at least one microporous surface region forms a uniformly extended lattice pattern on the polishing surface. 13. The coated abrasive article of any one of claims 8 to 12, wherein at least a portion of the abrasive composite comprises a pyramid. 14. A coated abrasive article according to any one of claims 8 to 13, comprising a coated abrasive disc or a coated abrasive belt.

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