SE528192C2 - Abrasive product with metal silicates or metal sulphates as antifouling agent and process for its preparation - Google Patents

Abstract

An abrasive is oversized with a layer consisting essentially of an inorganic anti-loading agent selected from the group consisting of metal silicates, silicas, metal carbonates, and metal sulfates. The metal silicates can be selected from the group consisting of magnesium silicates, potassium aluminum silicates, aluminum silicates, and calcium silicates. In one embodiment, the magnesium silicates include talc, the potassium aluminum silicates include micas, the aluminum silicates include clays, and the calcium silicates include wollastonite. The silicas can be selected from the group consisting of fused silica, fumed silica, and precipitated amorphous silica. The metal carbonates can inlude calcium carbonate. The metal sulfates can inlcude hydrous calcium sulfate or anhydrous calcium sulfate.

Description

528 528 192 the anticoagulant is applied.

The metal silicates can be selected from the group consisting of magnesium silicates, potassium aluminum silicates, aluminum silicates and calcium silicates. In one embodiment, the magnesium silicates include talc, the potassium aluminum silicates include mica, the aluminum silicates include clays, and the calcium silicates include wollastonite. The metal sulphates may include aqueous calcium sulphate or anhydrous calcium phosphate. The antifouling agent may have a hardness of less than according to Mehe hardnesseekeie eeh preferably less than eirke s. This allows the anti-clogging agent to form sufficiently small particles to combine with the chips on a surface of the coated abrasive product. This means that in the anti-clogging agent it is of such a size that particles from the medium sanding of a painted surface using the coated abrasive product are thus formed combined with and prevent agglomeration thereof; in.

In a further embodiment, the anti-clogging agent -f - is concentrated. hovedudeekngen in överbenggeingeekakeet. For example, keeeenaetie vara ee vara. at least 10% by volume and preferably at least about 60% by volume of ¿¿Å-f f * tet. and radiation curing resin systems; In addition, there is provided an abrasive product, such as a coated composite abrasive product, which includes a carrier layer having an ear surface, an abrasive layer having a plurality of abrasive grains disposed on the first surface of the carrier layer and a layer consisting substantially of an inorganic anti-corrosion agent. In one embodiment, the anti-caking agent is placed on a cured adhesive layer.

In addition, there is provided a method of forming an abrasive product such as a coated abrasive product or a composite abrasive product which comprises applying a plurality of abrasive grains to the first surface of a first carrier layer and placing a layer consisting essentially of an anti-clogging agent over the abrasive grains; The antifouling agent is preferably dispersed in a d: 1 includes, for example, a thermoplastic or thermosetting agent. * f is selected 'from the group consisting of urea formaldehyde, phenolic pulp "," from _10 15 20 25 30 528 192 Brief Description of the Drawings The accompanying drawings are not necessarily to scale, but the emphasis here is on illustrating the principles of the invention.

DETAILED DESCRIPTION OF THE INVENTION Coated abrasive products generally include abrasive grain loaded products on a carrier which may, for abrasive or otherwise abrasion, wear an article to which they are applied.

The carrier in a coated abrasive product may be rigid but is generally'_flexible_ and - typically includes a network of materials such as paper, cloth, p_ ¿. _., polymer fi lm, vulcanized fi ber or a combination of such. similar. In some applications, the carrier initially comprises a collection of solvents to which the abrasive grains are added, with or without additional binder, so that the abrasive grains are provided with abrasive grains throughout. The loose collection fi ber ,, ll * f «I fi". »Can be compressed, if no" adhesive "is included, or on. preferably _ the workpiece. and includes sand, il fl intkorn, -korxind, _vmetallonidev'såsom _ »_ 5"; . aluminum alumina, aluminum zirconia, ceramic aluminum oxy »: silicon carbide, garnet, polishing red, Parisian red and the like. The grains have sharp edges and edges that act as grinding means, but the quality and number of sharp edges ~ depends on the use. The grains may be embedded in or incorporated into the carrier, but are usually attached to the carrier with a suitable binder. The grains can be applied or mixed into the fabric in a specific pattern or distributed randomly. Extensive measures are normally taken to ensure that the coated abrasive product has solid abrasive grains with a suitable distribution of granular cutting edges in one or more layers. i i The binder is generally any suitable material which attaches the abrasive grains to the carrier and can withstand the abrasive process. Typical 'binders' include phenolic resins, skin adhesives, varnishes, epoxy resins, acrylates, multifunctional. The drawing illustrates a contact angle 6 given a solid, _. __ layer. The function of this layer is to place on the surface of the coated abrasive product-528 in a close relationship with the wearer. In general, the adhesive is carefully selected to provide maximum efficiency of the coated abrasive product on the intended abrasive surface. Care is taken to choose binders that do not soften or burn or both due to overheating and still give _; adequate fastening.

The abrasive grains can be sprayed or otherwise coated with the binder and V deposited on or around the carrier, or the carrier can be coated with the binder and the grains thereon deposited thereon. . of a conventional coated abrasive product, an adhesive layer is applied, an adhesive resin is applied, and while the resin is in the adhesive, abrasive grains are applied over the primer layer and the adhesive wound is held in place by the abrasive grains. An after-adhesive layer, which mainly involves binder resin and any fillers, abrasive aids, and abrasive-like, is then applied over the abrasive grains and cured. The primary year of the post-adhesive layer. To anchor the abrasive grains in place and enable them to work in the workpiece without being pulled out of the coated abrasive product into an additive which gives a special property, for example, improved surface lubrication, antistatic properties or, in this case, , anti-corrosion properties. Normally the top layer does not affect the abrasive grain attachment in the * coated abrasive product, but such an effect is not excluded. The additive can be applied as a dispersion in a binder (which is then cured) or in a surface dispersion which simply dries and leaves the additive on the surface. In one embodiment, the binder comprises a thermoplastic or thermosetting resin. The thermoplastic resin may, for example, contain latex and the thermosetting resin may be selected from the group consisting of urea formaldehyde, phenolic pulp, epoxy, urethane and radiation curing resin systems.

With certain additives, adhesion to the surface can be achieved without the need for a dispersion medium. In accordance with the present invention, the anti-corrosion agents applied on top of the post-adhesive layer can be selected from the group consisting of metal silicates and metal sulphates. The metal silicates can be selected from the group consisting of magnesium silicates, potassium aluminum silicates, aluminum silicates and calcium silicates. In one embodiment, the magnesium silicates include talc, the potassium aluminum silicates glitter, the aluminum silicates clays and the calcium silicates wollastonite. The metal sulfates may include aqueous calcium sulfate or anhydrous calcium sulfate.

In accordance with the present invention, the inorganic anti-gum agent appears. during the course of use läletting 30 na 30111 __ the coating abrasive particles generated in the grinding process so as to prevent these from agglomerating and forming disturbing larger 3601110 ', The clogging of the coated abrasive product reduces the fact that this gives rise to the problems associated with conventional stearate-containing anti-clogging agents. derllïšlïill fl dfålf .. the surface, and this layer iörsvárari to a large extent subsequent grinding or polishing of the surface if it is not removed.

The anti-caking agent is relatively soft and has, for example, a hardness of less than about a degree of hardness and is preferably less than ash in an embodiment; The settling agent has an average particle diameter of less than about 30 microns, preferably between about 1 and about 20 micrometers, because material sizes appear to work better as anti-freezing agents. . »In that property is that the anti-clogging agent prevents abrasive chips particles from adhering to each other and that the clogging therefore decreases. The anti-clogging approach gives a dusty abrasion, while grinding without the inorganic anti-clogging agent tends to give abrasive chips such as balls or large chips that get stuck between the abrasive grains, preventing effective abrasion and reducing the life of the coated abrasive product. The difference in the appearance of the abrasive chips that occur when sanding with stearate-containing and non-stearate-containing products is visible.

According to the present invention, the concentration of anti-clogging agent in a coating surface in the overcoat layer is greater than about 10% by volume and preferably greater than about 60%. This ensures that the anti-clogging agent is sufficiently present to have the effect of providing the dust which prevents the abrasive chips from agglomerating.

The anti-clogging agent can be used with other abrasive products such as composite abrasive products (with ert grade).

Example 1: Aqueous 1; magnesigsilikgt (talc) at various median particlesß * 1 play In the example below and the following examples, a conventional-grade fi abrasive product of standard type is used. The carrier material is an A-weight paper and the post-adhesive layer comprises a urea-formaldehyde binder. I fell sfi pmeaenpartikiuna Pazo-aiuminiumoxia. On 'this coated bass fi pprbaukt ~ v; an overcoating sieve is applied which includes an anti-clogging component as an additive. In one case, no additive was applied for other purposes. . case was an overcoat containing zinc stearate second applied? . In this case, the coating applied was aqueous magnesium silicate. in different particle sizes. The additives were applied as a dispersion of water. the mean value of the surface roughness), was also determined. The results are reproduced in Tahell tet.

The coated abrasive products were then used to grind a 'f ïï' f b a double-acting surface grinding machine 'through six contacts at' every f:: - minute intervals; The grinding is done with a 12.7 ~ cm. (5 inch) disc 2 lf (10 lb) load. The amount of sanded away material after a total sanding time was recorded, and the sanding performance was measured as a percentage sanded away V ”with the control. 'The average values of surface roughness, Ra (det-f and show that talc is as effective as the more conventionally used' zinc stearal 'i'. 10 15 20 25 30 o 528 192 An fi again- No zinc- maznesium- masneßi fl m- fl fàß fl e fl lum 'mata-id s fl ika: (talk) a fl ikm (talk) smkat (talk) Parameter Bas- Zinc- Vertal Supreme control Sena: 1500 HT Mwt Meaianpar fi- N / A 5.6 micron 15 mile-on 7 macron 1.9 micr fl n kel size for anti-corrosion agent _ Bexäggmngens N / A 14.80 ~ 1s, a2 ~ 13.32 ~ 1§§32 una-vikt ^ a ~ “A (glmß) .w '_ Fyumdsme- N / A ao s1 s1 _ 81: 1 delsvolym% ij (antiigensätt- ~ ^ 'níngsmedel) ^ -_ »Binaemeaelßf N / A 9,05 11 11 1 * 1_if - volym%' i .f Bmslipa: ma- 1oo% 136% 121% 134%, A1a7g-.Vf term (% of 'e' control) W Yuahet, Ra 0.46 0.41 0.46 0.46 10.465 'É-ff' (llm) 'Table 1 Vertal 1500, Supreme HT and Arctic Mist are talc preparations that - lï-lï _. "- from Luzenac America, Inc.

Moisture content ",," ('1'abell. 2, Table 3 and Table 4 respectively). The results show that the abrasion became greater with the incorporation of the anti-caking agent according to the present method compared to the base control, especially for smaller grain sizes. 10 15 20 528 192 Table 3 8 P80 Base control Witco Zn-St- Supreme dispersion HT -t fl lk 'Dry weight of the coating N / Ai 14.80 "1332' (g / mz), Fynmdsmeaelsvolm% N / A 90 81 (anti-corrosive agent) Binder volume% N / A 9.05 11 _ Cumulated bofts fi pat 21.81 24.48 22.54 material (g) 'f, isomupatmaveria; i 100% 118% j1b4g5 i: _,% of control N _ u _ Ramn) '1,88 i, 1,98 2, ó5 »- ~ 1h ~. i Table 2 P180, vßaskontroll Witco Zn-St- 'f H dispersion HTåtalkv V Beläggningens mmm N / A 14,80' ~ 1såášfi i '(g / mä Fyllnadsmedelsvolym% N / A 90 _ (antiigensättningsmedel), i V, Binaemede1sv01ym% , N / A 9.05,.

Cumulative sanded away 15.87 23.5. ~ f material (g), _ "_ji i; Borzslipac material 100% 148% 125% * -% - of control Rà (um) 0.84 0.89 10 15 20 * B28 192 9 P320 Base control Witco Zn-St- Supreme dispersion HT talc Coating weight N / A 14.80 ~ 13.32 (g / mlz) l Filler volume% N / A 90 81 (anti-clogging agent) Binder volume% 'N / A 9.05 l 11 Cumulated sanded away 7.75 13 .12 12.93 material (g) »Boi-tampas material 100% .174% 167%; l '1 _', 1% of control l 'Ra (pm) 0.46 0.41 Table 4 l Example 3: Anliorf '' '' '' '_ _ (legal and kggumalgngn' umgilikat gglimmer).: F A conventional coated abrasive product of standard type with P320- * caffeine size, l <lll A-weight paper and alumina is used. On this coated basil lily product; ' an overcoat layer is applied which includes an anti-clogging agent additive of either amorphous silica, calcium silicate (wollastonite), cat (clay) or potassium aluminum silicate (mica). gre vid l .f satmingsmeaf fl enlig: "förengganae invention compared with baskontlgçšlfië fl iíïg: Ål l 10 15 20 25 30 528 192 10 Antiigen- N / A Amorphous Calcium- Water- Yattenha-l- Waterhßl fi gl? säfmmgs- laselaioxia 11111111 fi- m am- ngtalym- kßghym fl lflf fl l- material minium- niumsih- silicate cat (clay) cat (Ehmw (clay) DIGI) Parameter Bas- MN-23 Wolla- Opti- 31118989 Mica 325 control muita white 17 Bemgg white / A 4.44 51.80 7.40 16.28 2.96 dry weight (s / mg) Fynnaasme- N / A si ss so 79 4 _79- delsvolym% (antiigenaätt-ningsmiddel), Bmaemeaem- N / A 12 10 12 12 '[12 Bertslipat ma- 100%' 101% 113% 179% 113% A_: 1f40% »jj =; = j '^ teria1. (% av' '' Ü - “'' konuquy _ _ g.

Y fi åhetna 0.01 0,51 0,43 ~ _0, sà ~ 0,61 j038í7ff ~ ~ (pm) _.

Table 5 MN-23 amorphous silica available from Eagle Pitcher. i - Wonaswne 325 is kaiciums fl ikat augangugf from NYco Minemb, Ina Optiwhite is a clay available from Burgess Pigment Company.

Burgess 17 is a clay available from Burgess Pigment Companyf Q A Mica 325 is mica available from Oglebay Norton »Specialty Example 4: Calcium sulfate (weightless and aqueous). A, A conventional coated standard abrasive product with P320 grain size, A-weight paper and alumina is used. An overcoat layer is applied to this coated base abrasive product, which includes an anti-clogging additive; calcium sulphate (aqueous or aqueous). The results, given in Table 6 below, show that the abrasion was higher when incorporating the anticoagulant of the present invention compared to the base control. 10 15 20 25 30 i 528 fl 92 11 Ant fi gensäanings- vaaen fi ie vatuenhal fi gt i material kalcium sulphate kalciumslilfat 'Parameter Baskonuon sNoW WHITE TERRA ALBA.

Coat dry weight N / A 34.04 29.60 (g / mo Filler volume% N / A 76 82 (anti-clogging agent) Binder volume l% N / A 14 9 Abrasive material 100% 153% 141%% of control.

Yuàhet, Ra (om) o, 51 0,41 i 0,431 ._ I H “Table e 'f sNow wmTE är ett vauen fi-: m knçiumsmfat tmgängugt från Unifteçl .States Gypsum Company.

TERAA ALBA ett vaaenhal fi gu kalciumsmfat: ingångna fi ån Un1§ <1§'s§¿tfeef ¿Gypsum Company.

Eczema el ° was used for each coated abrasive product. A drop of water is then placed on each of the freshly ground discs and on an unpolished disc and the contact angle sensitive to the description in the Figure was measured. The contact angle is the angle a V, wet surface and a solid surface at the contact line. Table 7 and clearly indicates that the disc ground with a coated abrasive product according to the present invention had substantially less contact angle than the disc ground with a coated "anti-corrosion layer. The coated abrasive product" with a conventional anti-clogging layers of zinc stearate clearly deposited a low surface energy residue whose presence was indicated by the very large water contact angle, the consequence of which is that paints applied to such a surface do not easily wet the surface and this gives surface effects.

Primer disks were ground with P320-coated abrasive products with. magnetic potassium silicate calcium material silicon silicate aluminum in Slate (talc) silicate (glitter) 'V Parameter Bas- zinc- Supreme Mic-a 325 Wol1asto-_ SNOW- control stearate HT nite WHITE 5 Coating NIA 14.80 ~ 7,4o-17,7s 2,96 51.80 34.04 mmm (g / mz) Fynnadsme- N / A i so 's1 ve aa .v64 delsvolym% - (antiígensätt- ningemedel) Bmdsmeaels- N / A 9,05 11 12 1o 14 'in volume% V _ in Konmkryinkel 115 140 114 119 see; iörvatten' ~ ”15 (degrees) Table 7% 'Contact angle for; water on the disc sam not, had snpacs This invention has been specifically shown' and described with preferred embodiments, but those skilled in the art will recognize that various forms and details of the invention may be made without departing from the scope of the invention as such. take the fi nieras in the appended patent claims,

Claims (1)

1. 0 15 20 25 30 «528 192 13 ~ PATENT CLAIMS 1. Abrasive product characterized in that it is coated with an overlay: in coating layers consisting mainly of! in (a) a thermoplastic or thermosetting resin and in (b) an inorganic anti-corrosive agent selected from the group consisting of; l '' in l-1 metal silicates and metal sulphates. "I" Abrasive product according to claim 1 wherein the metal silicates are selected from the "i" consisting of magnesium silicates, potassium aluminum silicates, silicates and calcium silicates. Abrasive product according to claim 2 wherein the magnesium silicates include talc; 'i i 4. Slipproduktenugtpaænmavzvarikaiiumaiuminiums fl ikazer fi aiabegripvçr glimmar. 5. suppmam according to pawnnkmvzvarivalummiums fl ikaæma mbaígpipejßrïliemr; A abrasive product according to claim 2 wherein the calcium silicates are in wollastonite. V *. An abrasive product according to claim 1 wherein the metal sulphates include calcium sulfate or anhydrous calcium sulphate. The abrasive product of claim 1 wherein the anti-caking agent has a hardness value of less than about 7 according to the Mohs hardness scale. The abrasive product of claim 1 wherein the anti-caking agent is the resin agent; in __ g particle diameter which is less than 30 micrometers. The abrasive product of claim 11 wherein the anti-glare agent has a particle diameter in the range of 1 to 20 micrometers. Abrasive product according to claim 1, wherein abrasive product according to claim 1, wherein the anti-clogging agent is concentrated mainly on the overcoat layer. at least Û. 60% by volume of the overcoating layer 14. Abrasive product according to claim 1 in which the particles in the antifouling agent * are of such a size that when abrasive chips are produced during grinding. A painted surface with the coated abrasive product also releases particles of the antifouling agent which A abrasive product according to claim 1 wherein the abrasive is selected from the group consisting of coated abrasive products and composite abrasives 16. The abrasive product according to claim 1, wherein the layer consists essentially of: a thermoplastic resin; 'and an inorganic anti-caking agent on., in a group consisting of metal silicates and metal sulphates. latex. The abrasive product of claim 1 wherein the thermosetting resin is selected from the group consisting of urea formaldehyde, phenolic pulp, epoxy, urethane or radiation curing resin systems. i i '19. Abrasive product which is characterized by the fact that it consists of! (a) a carrier layer having a first surface, in 1 ": i (b) an abrasive layer having a plurality of abrasive grains placed fl on the first surface of the carrier. and an abrasive product according to claim 1 wherein the thermoplastic resin comprises in. (C) a layer consisting essentially of a thermoplastic or thermosetting resin and an inorganic antifouling agent, which is placed over the abrasive layer, the antifouling agent being selected from the group consisting of metal silicates and metal sulfates. The abrasive product according to claim 19 in which the particles in the abrasive are of such a size that when abrasive chips are produced on grinding a painted surface of the painted surface of the particle surface, the metal silicates are selected from the sfÜPP consisting of magnesium silicates, potassium aluminum silicate silicates and calcium silicates. of the anti-clogging agent which are combined with and prevent agglomeration thereof in abrasive chips. nde fi irbildningaven abrasive product which method of I in I. that it involves _, (a) bonding a plurality of abrasive grains on an Ersta ettïf I carrier layer; and (b) depositing a layer over the abrasive grains which consists essentially of: p. _ _. _ a thermoplastic or thermosetting resin; and V 1 (ii) an anticoagulant selected from the group * as; ' A process according to claim 22 wherein the metal silicates are selected from the group consisting of magnesium silicates, potassium aluminum silicates, aluminum silicates and calcium silicates A process according to claim 23 wherein the magnesium silicates comprise talc A process according to claim 22. further comprising the step of depositing an intermediate layer comprising a thermoplastic or thermosetting * ii over the abrasive grains in depositing the layer in step (b). The method of claim 22 further comprising the step of forming an abrasive surface on the abrasive product which is such that the anti-clogging agent is mainly present on this surface. In a method according to claim 22- which further "in I -disperse of which the anticoagulant in the ternioplastic or thermophilic ill šillïïfïe f resin.