Thermosetting binder for an abrasive article

Claim 2

An abrasive article comprising: (a) a plurality of abrasive grains; and (b) at least one binder for the abrasive grains, wherein the binder comprises a cured precursor, wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR14## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR15## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i) and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b)(i) is defined such that it does not include the modifying component of element (b)(ii), and wherein the curing agent of element (b)(iv) is defined such that it does not include the modifying component of element (b)(iii).

Claim 3

The abrasive article of claim 1 wherein the (b)(ii) modifying component is selected from the group consisting of: ##STR16## wherein X comprises an epoxy group and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to the polymerization of epoxide group containing compounds; Q is selected from the group consisting of CR 3 2 , CO, S SO SO 2 , O, and NR 3 ; wherein R 3 is independently selected from the group consisting of H and alkyl groups comprising 1 to 4 carbon atoms.

Claim 4

The abrasive article of claim 1 wherein the (b) (iii) modifying component is selected from the group consisting of: ##STR17## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, --NCH 3 --, --O--, --S--, and --COO--; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to the polymerization of epoxy group containing components; Q is selected from the group consisting of CR 3 2 , CO, S, SO, SO 2 , O and NR 3 ; wherein R 3 is independently selected from the group consisting of H and alkyl groups comprising 1 to 4 carbon atoms.

Claim 5

The abrasive article of claim 1 wherein said modifying component of element (b)(ii) has the formula ##STR18## wherein each R 0 and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to the polymerization of epoxy group containing compounds.

Claim 6

The abrasive article of claim 1 wherein said modifying component of element (b)(iii) has the formula ##STR19## wherein Y is independently selected from the group consisting of --NH--, --NCH 3 --, --O--, --S--, --COO--, and mixtures thereof.

Claim 7

The abrasive article of claim 1 wherein said binder precursor further comprises about 2 to about 30 percent by weight of a toughening agent based upon the total weight of the precursor composition.

Claim 8

The abrasive article of claim 6 wherein said toughening agent is selected from the group consisting of carboxylated acrylonitrile/butadiene vulcanizable elastomer precursors, isocyanate-functional polyethers, and functional acrylic rubbers.

Claim 9

The abrasive article of claim 1 wherein said epoxy resin comprises an aromatic polyepoxide.

Claim 10

The abrasive article of claim 1 wherein said binder precursor further comprises an additive selected from the group consisting of fillers, grinding aids, and mixtures thereof.

Claim 11

The abrasive article of claim 1 wherein the precursor comprises one of the following combination of components selected from the group consisting of: about 90 to about 10 percent by weight (i), about 95 to about 10 percent by weight (ii), about 10 to about 50 percent by weight (iii), about 1 to about 40 percent by weight (iv); about 90 to about 50 percent by weight (i), about 90 to about 5 percent by weight (ii), about 10 to about 50 percent by weight (iii); about 90 to about 50 percent by weight (i), about 95 to about 5 percent by weight (ii), about 1 to about 40 percent by weight (iv); about 90 to about 50 percent by weight (i), about 10 to about 50 percent by weight (iii); about 99 to about 60 percent by weight (ii), about 10 to about 50 percent by weight (iii), about 1 to about 40 percent by weight (iv); about 90 to about 50 percent by weight (ii), about 10 to about 50 percent by weight (iii); about 99 to about 60 percent by weight (ii), about 1 to about 40 percent by weight (iv); about 90 to about 50 percent by weight (i), about 10 to about 50 percent by weight (iii), about 1 to about 40 percent by weight (iv); wherein the weight percentages for each combination are based upon the total weight of the precursor.

Claim 12

The abrasive article of claim 1 wherein the precursor comprises one of the following combination of components selected from the group consisting of: about 75 to about 10 percent by weight (i), about 75 to about 10 percent by weight (ii), about 15 to about 50 percent by weight (iii), about 1 to about 20 percent by weight (iv); about 75 to about 10 percent by weight (i), about 75 to about 10 percent by weight (ii), about 25 to about 50 percent by weight (iii); about 75 to about 10 percent by weight (i), about 75 to about 10 percent by weight (ii), about 1 to about 20 percent by weight (iv); about 85 to about 50 percent by weight (i), about 15 to about 50 percent by weight (iii); about 75 to about 50 percent by weight (ii), about 25 to about 50 percent by weight (iii), about 1 to about 20 percent by weight (iv); about 75 to about 50 percent by weight (ii), about 25 to about 50 percent by weight (iii); about 95 to about 70 percent by weight (ii), about 5 to about 30 percent by weight (iv); about 85 to about 50 percent by weight (i), about 15 to about 50 percent by weight (iii), about 1 to about 20 percent by weight (iv); wherein the weight percentages for each combination are based upon the total weight of the precursor.

Claim 13

The abrasive article of claim 1 wherein said abrasive article comprises a coated abrasive article.

Claim 14

The coated abrasive article of claim 12 wherein said coated abrasive article has a substrate comprising a backing comprising aramid fibers.

Claim 15

The abrasive article of claim 1 wherein said abrasive article comprises a nonwoven abrasive article.

Claim 16

The abrasive article of claim 1 wherein said abrasive article comprises a bonded abrasive article.

Claim 17

The abrasive article of claim 1 wherein said precursor further comprises a thermosetting resin selected from the group consisting of phenolic resins, urea-formaldehyde resins, melamine formaldehyde resins, latices, urethane resins, aminoplast resins, acrylate resins, epoxy resins, isocyanate resins, and mixtures thereof.

Claim 18

A nonwoven abrasive article comprising a plurality of abrasive grains bonded into a nonwoven web by a binder wherein the binder comprises a cured precursor wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR20## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR21## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i) and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b)(i) is defined such that it does not include the modifying component of element (b)(ii), and wherein the curing agent of element (b)(iv) is defined such that it does not include the modifying component of element (b)(iii).

Claim 19

A nonwoven abrasive article comprising a plurality of abrasive grains bonded into a nonwoven web by a binder wherein the binder comprises a cured precursor wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR20## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR21## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i) and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b)(i) is defined such that it does not include the modifying component of element (b)(ii), and wherein the curing agent of element (b)(iv) is defined such that it does not include the modifying component of element (b)(iii).

Claim 20

A bonded abrasive article comprising a plurality of grains bonded together by a binder to form a shaped mass wherein the binder comprises a cured precursor, wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR22## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR23## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i) and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b)(i) is defined such that it does not include the modifying component of element (b)(ii), and wherein the curing agent of element (b)(iv) is defined such that it does not include the modifying component of element (b)(iii).

Claim 21

A bonded abrasive article comprising a plurality of grains bonded together by a binder to form a shaped mass wherein the binder comprises a cured precursor, wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR22## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR23## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i) and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b)(i) is defined such that it does not include the modifying component of element (b)(ii), and wherein the curing agent of element (b)(iv) is defined such that it does not include the modifying component of element (b)(iii).

Claim 22

A coated abrasive article comprising: (a) a substrate having a front side and a back side; (b) at least one layer of abrasive grains bonded to said front side of said substrate by means of a make coat; (c) optionally one or more additional coats selected from the group consisting of a size coat, a supersize coat, a saturant coat, a presize coat, and a backsize coat; wherein at least one of said make, size, supersize, saturant, presize, and backsize coats comprises a cured precursor, wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR24## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR25## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i) and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b)(i) is defined such that it does not include the modifying component of element (b)(ii), and wherein the curing agent of element (b)(iv) is defined such that it does not include the modifying component of element (b)(iii).

Claim 23

A coated abrasive article comprising: (a) a substrate having a front side and a back side; (b) at least one layer of abrasive grains bonded to said front side of said substrate by means of a make coat; (c) optionally one or more additional coats selected from the group consisting of a size coat, a supersize coat, a saturant coat, a presize coat, and a backsize coat; wherein at least one of said make, size, supersize, saturant, presize, and backsize coats comprises a cured precursor, wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR24## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR25## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i) and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b)(i) is defined such that it does not include the modifying component of element (b)(ii), and wherein the curing agent of element (b)(iv) is defined such that it does not include the modifying component of element (b)(iii).

Claim 24

A coated abrasive article comprising: (a) a cloth substrate having a front side and a back side; (b) at least one layer of abrasive grains bonded to said front side of said cloth substrate by means of a phenolic resin make coat; (c) one or more additional coats selected from the group consisting of a backsize coat, a saturant coat, and a presize coat; wherein one or more of said backsize, saturant, and presize coats comprises a cured precursor, wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR26## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR27## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i), and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b) (i) is defined such that it does not include the modifying component of element (b) (ii), and wherein the curing agent of element (b) (iv) is defined such that it does not include the modifying component of element (b) (iii).

Claim 25

A coated abrasive article comprising: (a) a cloth substrate having a front side and a back side; (b) at least one layer of abrasive grains bonded to said front side of said cloth substrate by means of a phenolic resin make coat; (c) one or more additional coats selected from the group consisting of a backsize coat, a saturant coat, and a presize coat; wherein one or more of said backsize, saturant, and presize coats comprises a cured precursor, wherein the precursor comprises: (i) optionally an epoxy resin; (ii) optionally a modifying component selected from the group consisting of modifying components of the general formula: ##STR26## wherein X represents an epoxy group; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iii) optionally a modifying component selected from the group consisting of the general formula: ##STR27## wherein X represents --YH; Y is independently selected from the group consisting of --NH--, NCH 3 --, --O--, --S--, and --COO--; R comprises a divalent linking group selected from the group consisting of polycyclic aryls, cyclic alkyls, and polycyclic alkyls; and R 1 is independently selected from the group consisting of hydrogen and other groups substantially inert to polymerization of epoxide group containing compounds; (iv) optionally a curing agent, wherein said precursor comprises one of the following combination of components selected from the group consisting of: (i), (iii), and (iv); (i), (ii), (iii), and (iv); (i), (ii), and (iii); (i), (ii), and (iv); (i), and (iii); (ii), (iii), and (iv); (ii) and (iii); and (ii) and (iv); wherein the epoxy resin of element (b) (i) is defined such that it does not include the modifying component of element (b) (ii), and wherein the curing agent of element (b) (iv) is defined such that it does not include the modifying component of element (b) (iii).