US3906684A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Abrasive articles and their method of manufacture
Assignee: Saint Gobain Abrasives Inc
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Filing: 1971-05-20
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Granted: 1975-09-23
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Expires: 1991-05-20
Abstract
Abstract Abrasive material is provided in which a relatively thick, flexible, porous, abrasive layer is secured adhesively to a flexible backing member. In the manufacture of the abrasive material, abrasive grain is first coated with a liquid resinous binder composition after which the coated grain is then mixed with a solid, particulate, resinous binder composition, the latter binder being more resistant, after curing, to distortion when subjected to heat and pressure. The thus-formed free-flowing abrasive mixture is then coated continuously onto a flexible backing member. Afterwards, the layer of abrasive mixture is heated to cause fusion of the solid binder at the interface with the liquid binder. It is then compacted into a relatively dense abrasive layer, and is wound up into a jumbo roll in which condition the abrasive layer is subjected to further heat to cure the binder material.
Inventors
- 👤 Charles W Marshall
- 👤 Loran A Henderson
- 👤 Jr William F Zimmer
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 03:16
CPC Classifications
C; C09; C09K; C09K3/00; C09K3/14; C09K3/1436; B; B24; B24D; B24D11/00; B24D11/001; B24D11/005; B24D3/00; B24D3/02; B24D3/20; B24D3/28; B24D3/285; B24D3/30; B29; B29C; B29C70/00; B29C70/02; B29C70/021; B29C70/025; B29C70/04; B29C70/28; B29C70/40; B29C70/50; B29C70/58; B29K; B29K2061/00; B29K2061/04; B29K2063/00; B29L; B29L2031/00; B29L2031/736
Claims Analysis
Total Claims: 29
Claim 1
Independent Claim
93 words
ABRASIVE MAERIAL COMPRISING A POROUS, COMPACTED ABRASIVE LAYER COMPRISING PARTICULAE ABRASIVE GRAINS EACH BEING ENCAPSULATED IN A FIRST BINDER MATERIAL, THE ENCAPSULATED ABRASIVE GRAINS BEING DISTRIBUTED THROUGHOUT THE ABRASIVE LAYER IN A MATRIX OF A SECOND BINDER MATERIAL, SAID SECOND BINDER MATERIAL BEING MORE RESISTANT TO DISTORTION THAN SAID FIRST BINDER MATERIAL UNDER PRESSURE AT THE TEMPERATURE ATTAINED DURING USAGE OF AN ABRASIVE ARTICLE COMPRISING THE ABRASIVE MATERIAL WHEREBY IN USAGE THE FIRST BINDER MATERIAL WILL BECOME HEATED AND DISTORTED SUFFICIENTLY THAT SAID ABRASIVE GRAINS WILL BE DESIRABLY SHED FROM THE ABRASIVE LAYER.
Claim 2
Dependent Claim
93 words
ABRASIVE MAERIAL COMPRISING A POROUS, COMPACTED ABRASIVE LAYER COMPRISING PARTICULAE ABRASIVE GRAINS EACH BEING ENCAPSULATED IN A FIRST BINDER MATERIAL, THE ENCAPSULATED ABRASIVE GRAINS BEING DISTRIBUTED THROUGHOUT THE ABRASIVE LAYER IN A MATRIX OF A SECOND BINDER MATERIAL, SAID SECOND BINDER MATERIAL BEING MORE RESISTANT TO DISTORTION THAN SAID FIRST BINDER MATERIAL UNDER PRESSURE AT THE TEMPERATURE ATTAINED DURING USAGE OF AN ABRASIVE ARTICLE COMPRISING THE ABRASIVE MATERIAL WHEREBY IN USAGE THE FIRST BINDER MATERIAL WILL BECOME HEATED AND DISTORTED SUFFICIENTLY THAT SAID ABRASIVE GRAINS WILL BE DESIRABLY SHED FROM THE ABRASIVE LAYER.
Claim 3
Dependent Claim
24 words
Abrasive material in accordance with claim 1 wherein said first binder material is distortable at a lower temperature than that attained during actual grinding.
Claim 4
Dependent Claim
105 words
mixing with said coated grain a predetermined proportion of a solid binder composition; b. coating the dry, free flowable abrasive mixture onto a suitable flexible backing member; c. spreading the abrasive mixture uniformly into a layer of relatively uniform thickness; d. heating the abrasive layer thereby to fuse said solid binder with said liquid binder; e. compacting the heated abrasive layer to a predetermined thickness; and f. heating further said compacted abrasive layer whereby to cure said binders, said first applied binder composition encapsulating each abrasive grain and being less resistant to distortion when heated than said binder in which the coated grains are mixed.
Claim 5
Dependent Claim
105 words
mixing with said coated grain a predetermined proportion of a solid binder composition; b. coating the dry, free flowable abrasive mixture onto a suitable flexible backing member; c. spreading the abrasive mixture uniformly into a layer of relatively uniform thickness; d. heating the abrasive layer thereby to fuse said solid binder with said liquid binder; e. compacting the heated abrasive layer to a predetermined thickness; and f. heating further said compacted abrasive layer whereby to cure said binders, said first applied binder composition encapsulating each abrasive grain and being less resistant to distortion when heated than said binder in which the coated grains are mixed.
Claim 6
Dependent Claim
31 words
Abrasive material in accordance with claim 1 further comprising a flexible backing member having a front side and a back side, said abrasive layer being adhesively secured to said front side.
Claim 7
Dependent Claim
27 words
Abrasive material according to claim 3 wherein said abrasive layer is at least as thick as the largest dimension of the largest grain in the abrasive layer.
Claim 8
Dependent Claim
20 words
Abrasive material according to claim 4 further comprising an adhesive layer interposed between said front side and said abrasive layer.
Claim 9
Dependent Claim
25 words
Abrasive material according to claim 5 wherein said first binder material softens with heat sufficiently to be distortable at a temperature greater than about 240*F.
Claim 10
Dependent Claim
14 words
Abrasive material according to claim 6 wherein said first binder material comprises epoxy resin.
Claim 11
Dependent Claim
21 words
Abrasive material according to claim 7 wherein the matrix binder resists distortion when heated even at the temperatures attained during grinding.
Claim 12
Dependent Claim
13 words
Abrasive material according to claim 8 wherein said matrix binder material comprises phenol-formaldehyde.
Claim 13
Dependent Claim
47 words
Abrasive material according to claim 9 wherein in said abrasive layer the abrasive grain comprises from about 38 to 52%, said first and second binder materials comprise from about 10 to 50%, and the remainder of said layer is voids, all of said percentages being by volume.
Claim 14
Dependent Claim
19 words
Abrasive material according to claim 10 wherein said abrasive layer has a thickness no greater than about 0.250 inch.
Claim 15
Dependent Claim
24 words
Abrasive material according to claim 11 wherein the density of the abrasive layer is less than the loose packed density of said abrasive grain.
Claim 16
Dependent Claim
20 words
Process for the manufacture of abrasive material including the following steps: a. preparing a dry, freely flowable abrasive mixture comprising:
Claim 17
Dependent Claim
20 words
Process for the manufacture of abrasive material including the following steps: a. preparing a dry, freely flowable abrasive mixture comprising:
Claim 18
Dependent Claim
20 words
Process for the manufacture of abrasive material according to claim 13 wherein said flexible backing member is a continuous web.
Claim 19
Dependent Claim
32 words
Process for the manufacture of abrasive material according to claim 14 wherein prior to coating said abrasive mixture onto the flexible backing member, said member is provided with a layer of adhesive.
Claim 20
Dependent Claim
17 words
Process for the manufacture of abrasive material according to claim 15 wherein said adhesive layer comprises phenol-formaldehyde.
Claim 21
Dependent Claim
26 words
Process for the manufacture of abrasive material according to claim 16 wherein said liquid binder composition comprises epoxy resin and said solid binder composition comprises phenol-formaldehyde.
Claim 22
Dependent Claim
20 words
Process for the manufacture of abrasive material according to claim 17 in which said liquid binder composition further comprises furfural.
Claim 23
Dependent Claim
40 words
Process for the manufacture of abrasive material according to claim 18 including winding said abrasive coated web into a roll prior to said further heating, said winding being performed so that the abrasive layer faces the center Of the roll.
Claim 24
Dependent Claim
40 words
Process for the manufacture of abrasive material according to claim 19 including moving said roll vertically upwardly during said winding thereby to maintain the abrasive coated web in a plane no more than 10* with respect to the horizontal plane.
Claim 25
Dependent Claim
34 words
Abrasive material according to claim 1 in which the abrasive layer further comprises a filler having a modulus lower than that of the matrix binder material whereby a more easily friable bond is obtained.
Claim 26
Dependent Claim
13 words
Abrasive material according to claim 21 wherein said filler is a reactive filler.
Claim 27
Dependent Claim
26 words
Process for the manufacture of abrasive material according to claim 13 wherein said solid binder composition is at least partially soluble in said liquid binder composition.
Claim 28
Dependent Claim
27 words
Process for the manufacture of abrasive material according to claim 13 wherein the weight ratio of liquid binder to solid binder varies from 1/3 to 1/4 .
Claim 29
Dependent Claim
26 words
Process for the manufacture of abrasive material according to claim 18 wherein the weight ratio of epoxy resin to furfural varies from 1/3 to 1/3 .
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-09-22 | 1979-03-24 | 1979-09-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-09-22 | 1983-03-24 | 1983-09-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-09-22 | 1987-03-24 | 1987-09-23 | $7700.00 | Window Closed / Lapsed |