US5178646A — Coatable thermally curable binder presursor solut…

Claim 1

Independent Claim 323 words

A coatable, thermally curable binder precursor solution comprising: (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance of the solution comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups or with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR12## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 2

Dependent Claim 323 words

A coatable, thermally curable binder precursor solution comprising: (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance of the solution comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups or with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR12## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 3

Dependent Claim 17 words

A solution in accordance with claim 1 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.

Claim 4

Dependent Claim 26 words

A solution in accordance with claim 1 wherein said thermally curable resin is selected from the group consisting of phenolic resins, urea-aldehyde resins, and mixtures thereof.

Claim 5

Dependent Claim 28 words

A solution in accordance with claim 3 wherein said thermally curable resin is a phenolic resin selected from the group consisting of novolak, resole, and resolated novolak resins.

Claim 6

Dependent Claim 23 words

A solution in accordance with claim 1 wherein at least one functional group reactive with the pendant methylol groups comprises an --NH-- group.

Claim 7

Dependent Claim 20 words

A solution in accordance with claim 1 wherein said reactive diluent has a molecular weight of at most about 300.

Claim 8

Dependent Claim 20 words

A solution in accordance with claim 1 wherein said reactive diluent has a molecular weight of at most about 600.

Claim 9

Dependent Claim 20 words

A solution in accordance with claim 5 wherein said reactive diluent has a molecular weight of at most about 300.

Claim 10

Dependent Claim 14 words

A solution in accordance with claim 4 wherein said phenolic resin is a resole.

Claim 11

Dependent Claim 24 words

A solution in accordance with claim 1 which further includes water in an amount sufficient to turn the resultant solution permanently milky in appearance.

Claim 12

Dependent Claim 28 words

A solution in accordance with claim 1 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to 100:1.

Claim 13

Dependent Claim 28 words

A solution in accordance with claim 1 wherein said thermally curable resin and reactive diluent are present in a weight ratio ranging from about 2:1 to about 100:1.

Claim 14

Dependent Claim 14 words

A solution in accordance with claim 1 wherein said solution further includes abrasive particles.

Claim 15

Dependent Claim 29 words

A solution in accordance with claim 1 wherein R 1 is 2-hydroxyethyl, R 2 and R 3 are linked to form an ethylene bridge and R 4 is hydrogen.

Claim 16

Dependent Claim 34 words

A solution in accordance with claim 1 wherein X is O, Y is NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is butyl and R 4 is hydroxyethyl.

Claim 17

Dependent Claim 34 words

A solution in accordance with claim 1 wherein X is O, Y is NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is ethyl, and R 4 is butyl.

Claim 18

Dependent Claim 53 words

A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR13## wherein R 6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.

Claim 19

Dependent Claim 41 words

A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR14## wherein x is an integer ranging from about 2 to about 20.

Claim 20

Dependent Claim 54 words

A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR15## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.

Claim 21

Dependent Claim 61 words

A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the formula ##STR16## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.

Claim 22

Dependent Claim 9 words

A cured version of the solution of claim 1.

Claim 23

Dependent Claim 369 words

An abrasive article comprising a plurality of abrasive grains dispersed and adhered within a binder, the binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR17## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said abrasive article is a nonwoven abrasive the molecular weight of the poly (oxyalkylene) amine is less than about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 24

Dependent Claim 369 words

An abrasive article comprising a plurality of abrasive grains dispersed and adhered within a binder, the binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR17## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said abrasive article is a nonwoven abrasive the molecular weight of the poly (oxyalkylene) amine is less than about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 25

Dependent Claim 16 words

The abrasive article of claim 22 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.

Claim 26

Dependent Claim 18 words

The abrasive article of claim 22 wherein said functional group reactive with the pendant methylol groups is --NH--.

Claim 27

Dependent Claim 38 words

An abrasive article in accordance with claim 22 wherein X is O, Y=NR 3 R 4 , R 1 is 2-hydroxyethyl, R 2 and R 3 are linked to form an ethylene bridge, and R 4 is hydrogen.

Claim 28

Dependent Claim 33 words

An abrasive article in accordance with claim 22 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is butyl and R 4 is hydroxyethyl.

Claim 29

Dependent Claim 33 words

An abrasive article in accordance with claim 22 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is ethyl and R 4 is butyl.

Claim 30

Dependent Claim 53 words

An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR18## wherein R 6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.

Claim 31

Dependent Claim 41 words

An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR19## wherein x is an integer ranging from about 2 to about 20.

Claim 32

Dependent Claim 54 words

An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR20## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.

Claim 33

Dependent Claim 62 words

An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR21## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.

Claim 34

Dependent Claim 30 words

An abrasive article in accordance with claim 22 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon nitride, and mixtures thereof.

Claim 35

Dependent Claim 22 words

An abrasive article in accordance with claim 22 wherein said coatable, thermally curable binder precursor solution further comprises a thermal curing catalyst.

Claim 36

Dependent Claim 16 words

An abrasive article in accordance with claim 33 wherein said thermal curing catalyst is benzoyl peroxide.

Claim 37

Dependent Claim 36 words

An abrasive article in accordance with claim 22 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.

Claim 38

Dependent Claim 15 words

An abrasive article in accordance with claim 22 wherein said article is a bonded abrasive.

Claim 39

Dependent Claim 347 words

A coated abrasive article comprising a backing upon which an abrasive coating comprising abrasive grains and binder is attached, said binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR22## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 40

Dependent Claim 347 words

A coated abrasive article comprising a backing upon which an abrasive coating comprising abrasive grains and binder is attached, said binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR22## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 41

Dependent Claim 17 words

The coated abrasive article of claim 37 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.

Claim 42

Dependent Claim 28 words

The coated abrasive article of claim 37 wherein said thermally curable resin is a phenolic resin selected from the group consisting of resole, novolak, and resolated novolak resins.

Claim 43

Dependent Claim 14 words

The coated abrasive article of claim 37 wherein said phenolic resin is a resole.

Claim 44

Dependent Claim 29 words

The coated abrasive article of claim 37 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to about 100:1.

Claim 45

Dependent Claim 29 words

The coated abrasive article of claim 37 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon carbide, and mixtures thereof.

Claim 46

Dependent Claim 18 words

The coated abrasive article of claim 37 wherein said binder precursor solution further comprises a thermal curing catalyst.

Claim 47

Dependent Claim 15 words

The coated abrasive article of claim 43 wherein said thermal coating catalyst is benzoyl peroxide.

Claim 48

Dependent Claim 35 words

The coated abrasive article of claim 42 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.

Claim 49

Dependent Claim 37 words

The coated abrasive article of claim 37 wherein X is O, Y=NR 3 R 4 , R 1 is 2-hydroxyethyl, R 2 and R 3 are linked to form an ethylene bridge, and R 4 is hydrogen.

Claim 50

Dependent Claim 32 words

The coated abrasive article of claim 37 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is butyl and R 4 is hydroxyethyl.

Claim 51

Dependent Claim 32 words

The coated abrasive article of claim 37 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is ethyl and R 4 is butyl.

Claim 52

Dependent Claim 53 words

The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR23## wherein R 6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.

Claim 53

Dependent Claim 41 words

The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR24## wherein x is an integer ranging from about 2 to about 20.

Claim 54

Dependent Claim 54 words

The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR25## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.

Claim 55

Dependent Claim 62 words

The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR26## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.

Claim 56

Dependent Claim 374 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating over the abrasive grains, wherein at least one of the make or size coatings is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR27## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 57

Dependent Claim 374 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating over the abrasive grains, wherein at least one of the make or size coatings is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR27## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 58

Dependent Claim 396 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating, over the abrasive grains, wherein said backing has at least one of a saturant coating, a presize coating, or a backsize coating, wherein at least one of said saturant coating, said presize coating, or said backsize coating is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR28## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 59

Dependent Claim 396 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating, over the abrasive grains, wherein said backing has at least one of a saturant coating, a presize coating, or a backsize coating, wherein at least one of said saturant coating, said presize coating, or said backsize coating is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR28## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.

Claim 60

Independent Claim 393 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) adhering abrasive grains to the fibers of the fibrous mat with a coatable, thermally curable binder precursor solution, said solution comprising a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water, and reactive diluent, thus producing a coated mat, said thermally curable resin being the reaction product of a non-aldehyde and an aldehyde, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR29## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said reactive diluent is a poly(oxyalkylene) amine, its molecular weight is less than about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; and (b) subjecting the coated mat to conditions sufficient to cure the binder precursor solution.

Claim 61

Independent Claim 393 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) adhering abrasive grains to the fibers of the fibrous mat with a coatable, thermally curable binder precursor solution, said solution comprising a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water, and reactive diluent, thus producing a coated mat, said thermally curable resin being the reaction product of a non-aldehyde and an aldehyde, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR29## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said reactive diluent is a poly(oxyalkylene) amine, its molecular weight is less than about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; and (b) subjecting the coated mat to conditions sufficient to cure the binder precursor solution.

Claim 62

Dependent Claim 53 words

A method in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR30## wherein R 6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.

Claim 63

Dependent Claim 41 words

A solution in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR31## wherein x is an integer ranging from about 2 to about 20.

Claim 64

Dependent Claim 54 words

A solution in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR32## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.

Claim 65

Dependent Claim 62 words

A solution in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR33## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.

Claim 66

Dependent Claim 26 words

A method in accordance with claim 55 further comprising applying a size coating to the abrasive coated mat of step (b) and curing the size coating.

Claim 67

Independent Claim 394 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) combining 30-95% solids solution of a thermally curable resin, the balance comprising water, with reactive diluent to form a coatable, thermally curable binder precursor solution, at a temperature below that necessary to cure the coatable, thermally curable binder precursor solution, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR34## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said reactive diluent is a poly(oxyalkylene) amine, its molecular weight is less than about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; (b) adding abrasive grains to the coatable, thermally curable binder precursor solution; (c) coating the abrasive-filled, coatable, thermally curable binder precursor solution onto at least a portion of the fibers of a lofty, open fibrous mat; and (d) heating the abrasive coated mat of step (c) to a temperature sufficient to cure the coatable thermally curable binder precursor solution.

Claim 68

Independent Claim 394 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) combining 30-95% solids solution of a thermally curable resin, the balance comprising water, with reactive diluent to form a coatable, thermally curable binder precursor solution, at a temperature below that necessary to cure the coatable, thermally curable binder precursor solution, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR34## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said reactive diluent is a poly(oxyalkylene) amine, its molecular weight is less than about 300; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; (b) adding abrasive grains to the coatable, thermally curable binder precursor solution; (c) coating the abrasive-filled, coatable, thermally curable binder precursor solution onto at least a portion of the fibers of a lofty, open fibrous mat; and (d) heating the abrasive coated mat of step (c) to a temperature sufficient to cure the coatable thermally curable binder precursor solution.

Claim 69

Independent Claim 339 words

A method of making a bonded abrasive article, said method comprising: (a) combining a coatable, thermally curable binder precursor solution comprising a 30-95% solids solution of a thermally curable resin, the balance comprising water, the resin having a plurality of pendant methylol group and made from the reaction product of a non-aldehyde and an aldehyde, and a reactive diluent with abrasive grains to form a mixture, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR35## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; and (b) subjecting the mixture of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 70

Independent Claim 339 words

A method of making a bonded abrasive article, said method comprising: (a) combining a coatable, thermally curable binder precursor solution comprising a 30-95% solids solution of a thermally curable resin, the balance comprising water, the resin having a plurality of pendant methylol group and made from the reaction product of a non-aldehyde and an aldehyde, and a reactive diluent with abrasive grains to form a mixture, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR35## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; and (b) subjecting the mixture of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 71

Dependent Claim 29 words

A method in accordance with claim 62 which further comprises introducing said abrasive grains, said binder precursor solution, and said reactive diluent into a mold prior to step (b).

Claim 72

Independent Claim 357 words

A method of making a coated abrasive article, said method comprising: (a) coating a backing with a coatable, thermally curable binder precursor solution comprising a 30-95% solid solution of a thermally curable resin, the balance comprising water, abrasive grains, and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR36## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000, thereby providing a coated backing; and (b) subjecting the coated backing of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 73

Independent Claim 357 words

A method of making a coated abrasive article, said method comprising: (a) coating a backing with a coatable, thermally curable binder precursor solution comprising a 30-95% solid solution of a thermally curable resin, the balance comprising water, abrasive grains, and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR36## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000, thereby providing a coated backing; and (b) subjecting the coated backing of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 74

Dependent Claim 33 words

A method in accordance with claim 64 wherein prior to step (a) water is added to the binder precursor solution in an amount sufficient to turn the resultant solution permanently milky in appearance.

Claim 75

Independent Claim 434 words

A method of making a coated abrasive article comprising the steps of: (a) applying a first coatable, thermally curable binder precursor solution to at least one major surface of a backing to form a make coating, the coatable, thermally curable binder precursor solution comprising a thermally curable resin and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR37## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; (b) subjecting the make coating to conditions sufficient to partially cure the make coating; (c) applying abrasive grains to the partially cured make coating of step (b) to form an abrasive coating; (d) applying a second coatable, thermally curable binder precursor solution which is the same as or different than the first coatable, thermally curable binder precursor solution to form a size coating over the abrasive coating of step (c); and (e) subjecting the structure of step (c) to a temperature sufficient to cure the first and second coatable, thermally curable binder precursor solutions.

Claim 76

Independent Claim 434 words

A method of making a coated abrasive article comprising the steps of: (a) applying a first coatable, thermally curable binder precursor solution to at least one major surface of a backing to form a make coating, the coatable, thermally curable binder precursor solution comprising a thermally curable resin and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR37## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; (b) subjecting the make coating to conditions sufficient to partially cure the make coating; (c) applying abrasive grains to the partially cured make coating of step (b) to form an abrasive coating; (d) applying a second coatable, thermally curable binder precursor solution which is the same as or different than the first coatable, thermally curable binder precursor solution to form a size coating over the abrasive coating of step (c); and (e) subjecting the structure of step (c) to a temperature sufficient to cure the first and second coatable, thermally curable binder precursor solutions.

Claim 77

Dependent Claim 19 words

A coatable, thermally curable binder precursor solution in accordance with claim 1 which further includes an ethylenically unsaturated monomer.

Claim 78

Dependent Claim 14 words

A cured version of the coatable, thermally curable binder precursor solution of claim 14.

Claim 79

Dependent Claim 21 words

An abrasive article in accordance with claim 22 wherein said coatable, thermally curable binder precursor solution includes an ethylenically unsaturated monomer.

Claim 80

Dependent Claim 21 words

The coated abrasive article of claim 36 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Claim 81

Dependent Claim 19 words

The method of claim 55 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Claim 82

Dependent Claim 19 words

The method of claim 62 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Claim 83

Dependent Claim 19 words

The method of claim 64 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Claim 84

Dependent Claim 296 words

A coatable, thermally curable binder precursor solution comprising: (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance of the solution comprising water; and (b) a reactive diluent; wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups or with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR38## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 85

Dependent Claim 296 words

A coatable, thermally curable binder precursor solution comprising: (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance of the solution comprising water; and (b) a reactive diluent; wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups or with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR38## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 86

Dependent Claim 17 words

A solution in accordance with claim 74 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.

Claim 87

Dependent Claim 26 words

A solution in accordance with claim 74 wherein said thermally curable resin is selected from the group consisting of phenolic resins, urea-aldehyde resins, and mixtures thereof.

Claim 88

Dependent Claim 28 words

A solution in accordance with claim 76 wherein said thermally curable resin is a phenolic resin selected from the group consisting of novolak, resole, and resolated novolak resins.

Claim 89

Dependent Claim 23 words

A solution in accordance with claim 74 wherein at least one functional group reactive with the pendant methylol groups comprises an --NH-- group.

Claim 90

Dependent Claim 14 words

A solution in accordance with claim 77 wherein said phenolic resin is a resole.

Claim 91

Dependent Claim 24 words

A solution in accordance with claim 74 which further includes water in an amount sufficient to turn the resultant solution permanently milky in appearance.

Claim 92

Dependent Claim 28 words

A solution in accordance with claim 74 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to 100:1.

Claim 93

Dependent Claim 28 words

A solution in accordance with claim 74 wherein said thermally curable resin and reactive diluent are present in a weight ratio ranging from about 2:1 to about 100:1.

Claim 94

Dependent Claim 14 words

A solution in accordance with claim 74 wherein said solution further includes abrasive particles.

Claim 95

Dependent Claim 29 words

A solution in accordance with claim 74 wherein R 1 is 2-hydroxyethyl, R 2 and R 3 are linked to form an ethylene bridge and R 4 is hydrogen.

Claim 96

Dependent Claim 34 words

A solution in accordance with claim 74 wherein X is O, Y is NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is butyl and R 4 is hydroxyethyl.

Claim 97

Dependent Claim 34 words

A solution in accordance with claim 74 wherein X is O, Y is NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is ethyl and R 4 is butyl.

Claim 98

Dependent Claim 9 words

A cured version of the solution of claim 1.

Claim 99

Dependent Claim 317 words

An abrasive article comprising a plurality of abrasive grains dispersed and adhered within a binder, the binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR39## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 100

Dependent Claim 317 words

An abrasive article comprising a plurality of abrasive grains dispersed and adhered within a binder, the binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR39## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 101

Dependent Claim 16 words

The abrasive article of claim 88 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.

Claim 102

Dependent Claim 18 words

The abrasive article of claim 88 wherein said functional group reactive with the pendant methylol group is --NH--.

Claim 103

Dependent Claim 38 words

The abrasive article in accordance with claim 88 wherein X is O, Y=NR 3 R 4 , R 1 is 2-hydroxyethyl, R 2 and R 3 are linked to form an ethylene bridge, and R 4 is hydrogen.

Claim 104

Dependent Claim 33 words

An abrasive article in accordance with claim 88 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is butyl and R 4 is hydroxyethyl.

Claim 105

Dependent Claim 33 words

An abrasive article in accordance with claim 88 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is ethyl and R 4 is butyl.

Claim 106

Dependent Claim 30 words

An abrasive article in accordance with claim 88 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon nitride, and mixtures thereof.

Claim 107

Dependent Claim 22 words

An abrasive article in accordance with claim 88 wherein said coatable, thermally curable binder precursor solution further comprises a thermal curing catalyst.

Claim 108

Dependent Claim 16 words

An abrasive article in accordance with claim 95 wherein said thermal curing catalyst is benzoyl peroxide.

Claim 109

Dependent Claim 36 words

An abrasive article in accordance with claim 88 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.

Claim 110

Dependent Claim 15 words

An abrasive article in accordance with claim 88 wherein said article is a bonded abrasive.

Claim 111

Dependent Claim 318 words

A coated abrasive article comprising a backing upon which an abrasive coating comprising abrasive grains and binder is attached, said binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent; wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR40## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 112

Dependent Claim 318 words

A coated abrasive article comprising a backing upon which an abrasive coating comprising abrasive grains and binder is attached, said binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent; wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR40## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 113

Dependent Claim 17 words

The coated abrasive article of claim 99 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.

Claim 114

Dependent Claim 28 words

The coated abrasive article of claim 99 wherein said thermally curable resin is a phenolic resin selected from the group consisting of resole, novolak, and resolated novolak resins.

Claim 115

Dependent Claim 14 words

The coated abrasive article of claim 99 wherein said phenolic resin is a resole.

Claim 116

Dependent Claim 29 words

The coated abrasive article of claim 99 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to about 100:1.

Claim 117

Dependent Claim 29 words

The coated abrasive article of claim 99 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon carbide, and mixtures thereof.

Claim 118

Dependent Claim 18 words

The coated abrasive article of claim 99 wherein said binder precursor solution further comprises a thermal curing catalyst.

Claim 119

Dependent Claim 15 words

The coated abrasive article of claim 105 wherein said thermal coating catalyst is benzoyl peroxide.

Claim 120

Dependent Claim 35 words

The coated abrasive article of claim 99 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.

Claim 121

Dependent Claim 37 words

The coated abrasive article of claim 99 wherein X is O, Y=NR 3 R 4 , R 1 is 2-hydroxyethyl, R 2 and R 3 are linked to form an ethylene bridge, and R 4 is hydrogen.

Claim 122

Dependent Claim 32 words

The coated abrasive article of claim 99 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is butyl and R 4 is hydroxyethyl.

Claim 123

Dependent Claim 32 words

The coated abrasive article of claim 99 wherein X is O, Y=NR 3 R 4 , R 1 and R 3 are hydrogen, R 2 is ethyl and R 4 is butyl.

Claim 124

Dependent Claim 346 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating over the abrasive grains, wherein at least one of the make or size coatings is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR41## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 125

Dependent Claim 346 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating over the abrasive grains, wherein at least one of the make or size coatings is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR41## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 126

Dependent Claim 369 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating, over the abrasive grains, wherein said backing has at least one of a saturant coating, a presize coating, or a backsize coating, wherein at least one of said saturant coating, said presize coating, or said backsize coating is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR42## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 127

Dependent Claim 369 words

A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating, over the abrasive grains, wherein said backing has at least one of a saturant coating, a presize coating, or a backsize coating, wherein at least one of said saturant coating, said presize coating, or said backsize coating is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and (b) a reactive diluent, wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR42## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes.

Claim 128

Independent Claim 345 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) adhering abrasive grains to the fibers of the fibrous mat with a coatable, thermally curable binder precursor solution, said solution comprising a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water, and reactive diluent, thus producing a coated mat, said thermally curable resin being the reaction product of a non-aldehyde and an aldehyde, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR43## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes, and (b) subjecting the coated mat to conditions sufficient to cure the binder precursor solution.

Claim 129

Independent Claim 345 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) adhering abrasive grains to the fibers of the fibrous mat with a coatable, thermally curable binder precursor solution, said solution comprising a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water, and reactive diluent, thus producing a coated mat, said thermally curable resin being the reaction product of a non-aldehyde and an aldehyde, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR43## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes, and (b) subjecting the coated mat to conditions sufficient to cure the binder precursor solution.

Claim 130

Dependent Claim 26 words

A method in accordance with claim 113 further comprising applying a size coating to the abrasive coated mat of step (b) and curing the size coating.

Claim 131

Independent Claim 347 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) combining 30-95% solids solution of a thermally curable resin, the balance comprising water, with reactive diluent to form a coatable, thermally curable binder precursor solution, at a temperature below that necessary to cure the coatable, thermally curable binder precursor solution, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR44## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; (b) adding abrasive grains to the coatable, thermally curable binder precursor solution; (c) coating the abrasive-filled, coatable, thermally curable binder precursor solution onto at least a portion of the fibers of a lofty, open fibrous mat; and (d) heating the abrasive coated mat of step (c) to a temperature sufficient to cure the coatable thermally curable binder precursor solution.

Claim 132

Independent Claim 347 words

A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising: (a) combining 30-95% solids solution of a thermally curable resin, the balance comprising water, with reactive diluent to form a coatable, thermally curable binder precursor solution, at a temperature below that necessary to cure the coatable, thermally curable binder precursor solution, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR44## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; (b) adding abrasive grains to the coatable, thermally curable binder precursor solution; (c) coating the abrasive-filled, coatable, thermally curable binder precursor solution onto at least a portion of the fibers of a lofty, open fibrous mat; and (d) heating the abrasive coated mat of step (c) to a temperature sufficient to cure the coatable thermally curable binder precursor solution.

Claim 133

Independent Claim 310 words

A method of making a bonded abrasive article, said method comprising: combining a coatable, thermally curable binder precursor solution comprising a 30-95% solids solution of a thermally curable resin, the balance comprising water, the resin having a plurality of pendant methylol groups and made from the reaction product of a non-aldehyde and an aldehyde, and a reactive diluent with abrasive grains to form a mixture, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR45## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; (b) subjecting the mixture of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 134

Independent Claim 310 words

A method of making a bonded abrasive article, said method comprising: combining a coatable, thermally curable binder precursor solution comprising a 30-95% solids solution of a thermally curable resin, the balance comprising water, the resin having a plurality of pendant methylol groups and made from the reaction product of a non-aldehyde and an aldehyde, and a reactive diluent with abrasive grains to form a mixture, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR45## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; (b) subjecting the mixture of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 135

Dependent Claim 29 words

A method in accordance with claim 116 which further comprises introducing said abrasive grains, said binder precursor solution, and said reactive diluent into a mold prior to step (b).

Claim 136

Independent Claim 329 words

A method of making a coated abrasive article, said method comprising: (a) coating a backing with a coatable, thermally curable binder precursor solution comprising a 30-95% solid solution of a thermally curable resin, the balance comprising water, abrasive grains, and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR46## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; thereby providing a coated backing; and (b) subjecting the coated backing of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 137

Independent Claim 329 words

A method of making a coated abrasive article, said method comprising: (a) coating a backing with a coatable, thermally curable binder precursor solution comprising a 30-95% solid solution of a thermally curable resin, the balance comprising water, abrasive grains, and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR46## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; thereby providing a coated backing; and (b) subjecting the coated backing of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.

Claim 138

Dependent Claim 33 words

A method in accordance with claim 118 wherein prior to step (a) water is added to the binder precursor solution in an amount sufficient to turn the resultant solution permanently milky in appearance.

Claim 139

Independent Claim 406 words

A method of making a coated abrasive article comprising the steps of: (a) applying a first coatable, thermally curable binder precursor solution to at least one major surface of a backing to form a make coating, the coatable, thermally curable binder precursor solution comprising a thermally curable resin and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR47## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; (b) subjecting the make coating to conditions sufficient to partially cure the make coating; (c) applying abrasive grains to the partially cured make coating of step (b) to form an abrasive coating; (d) applying a second coatable, thermally curable binder precursor solution which is the same as or different than the first coatable, thermally curable binder precursor solution to form a size coating over the abrasive coating of step (c); and (e) subjecting the structure of step (c) to a temperature sufficient to cure the first and second coatable, thermally curable binder precursor solutions.

Claim 140

Independent Claim 406 words

A method of making a coated abrasive article comprising the steps of: (a) applying a first coatable, thermally curable binder precursor solution to at least one major surface of a backing to form a make coating, the coatable, thermally curable binder precursor solution comprising a thermally curable resin and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of A) compounds selected from the group consisting of compounds represented by the general formula ##STR47## and mixtures thereof wherein X=O or S and Y=--NR 3 R 4 or --OR 5 , such that when X=S, Y=NR 3 R 4 , each of R 1 , R 2 , R 3 , R 4 and R 5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that: (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups; (ii) R 1 and R 2 or R 1 and R 3 can be linked to form a ring structure; and (iii) R 1 , R 2 , R 3 , R 4 and R 5 are never all hydrogen at the same time; and B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; (b) subjecting the make coating to conditions sufficient to partially cure the make coating; (c) applying abrasive grains to the partially cured make coating of step (b) to form an abrasive coating; (d) applying a second coatable, thermally curable binder precursor solution which is the same as or different than the first coatable, thermally curable binder precursor solution to form a size coating over the abrasive coating of step (c); and (e) subjecting the structure of step (c) to a temperature sufficient to cure the first and second coatable, thermally curable binder precursor solutions.

Claim 141

Dependent Claim 19 words

A coatable, thermally curable binder precursor solution in accordance with claim 74 which further includes an ethylenically unsaturated monomer.

Claim 142

Dependent Claim 14 words

A cured version of the coatable, thermally curable binder precursor solution of claim 84.

Claim 143

Dependent Claim 21 words

An abrasive article in accordance with claim 88 wherein said coatable, thermally curable binder precursor solution includes an ethylenically unsaturated monomer.

Claim 144

Dependent Claim 21 words

The coated abrasive article of claim 98 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Claim 145

Dependent Claim 19 words

The method of claim 113 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Claim 146

Dependent Claim 19 words

The method of claim 116 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Claim 147

Dependent Claim 19 words

The method of claim 118 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1996-01-12	1996-07-13	1997-01-12	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2000-01-12	2000-07-13	2001-01-12	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2004-01-12	2004-07-13	2005-01-12	$7700.00	Window Closed / Lapsed

Coatable thermally curable binder presursor solutions modified with a reactive diluent, abrasive articles incorporating same, and methods of making said abrasive articles

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