CA2107955A1 - Abrasive composites having a controlled rate of erosion, articles incorporating same, and methods of making and using same - Google Patents

Abstract

Abstract of the Disclosure An abrasive composite is presented having a controlled rate of erosion, the composite comprising abrasive particles dispersed in the binder, wherein the binder comprises an addition polymerized resin having clay particles dispersed therein. Previously known abrasive composites do not abrade in a controlled fashion. The invention abrasive composite may be adhered to various substrates, including paper, cloth, polymeric films, and nonwovens. The clay particles allow the binder, and thus the composite, to controllably erode upon abrasion of a workpiece, thus exposing fresh abrasive particles to the workpiece.
Coatable compositions comprising clay particles dispersed in a binder precursor composition, and optionally containing abrasive particles, are also described, as well as methods of making and using the composites and articles.

Description

21079~a A~RA~IVE COMPOSITES ~AVDIG A CONTROLLED
RATE OF EROSION, AR~ICLE8 INCORPORATING 8AME, AND METHODS OF MARING ~ND U8ING 8ANE

This invention pertains to an abrasive article comprising a plurality of abrasive particles and a clay-modified binder. The addition of the clay allows the binder to exhibit a controlled rate of erosion.
Abrasive articles typically comprise a plurality 10 of abrasive particles and a binder. In coated abrasives the binder is coated onto a backing, and the binder may comprise conventional make and size resins which bond abrasive particles to the backing, or the abrasive particles may be dispersed in a slurry which 15 is coated onto a backing. In nonwoven abrasives, the binder bonds abrasive particles to the fibers of a nonwoven fibrous substrate.
In both coated and nonwoven abrasives, the binder may comprise a resinous adhesive (referred to 20 hereinafter as simply "resin"), and optionally other additives, such as inorganic fillers. Examples of typical resins include phenolic resins, aminoplast resins, urethane resins, epoxy resins, and the like.
Typically, during the manufacture of a coated 25 abrasive article, the resin is applied in a liquid state and subsequently solidified or cured. This curing process is usually accomplished by exposing the resinous adhesive to an energy source such as thermal energy, or radiation energy such as electron beam, 30 ultraviolet (W) light or visible light. In recent years, W light curable resinous adhesives have become of interest due to several advantages over thermally curable adhesives. These advantages include considerably faster cure times, lower capital 35 investments and lower energy costs.

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Recent patents disclose use of various radiation-cured resins but do not appreciate the interference that clays present to efficient radiation curing.
U.S. Pat. No. 4,318,766 (Smith) discloses 5 photocopolymerizable compositions which may contain "conventional non-basic fillers (e.g., silica, talc, glass, glass bubbles, clays, powdered metal such as aluminum, zinc oxide, e~c.) up to about 50% by volume or more." However, this patent does not mention the 10 effect clay fillers might have on curing of radiation-curable binders. Other patents include U.S. Patent Nos. 4,642,126; 4,644,703; 4,735,632; 4,751,138;
4,773,920; 4,903,440; 4,927,431; S,011,513; 5,014,468;
5,152,917.
Patents which appear to be concerned with erodability of binders but do not discuss clays and their possible effect on binder erodability are U.S
Pat. Nos. 2,806,772; 2,676,892; 4,58~,419; 4,652,275;
and 4,871,376.
Microabrasive products have been commercialized since 1987 by assignee Minnesota Mining and Manufacturing Company, St. Paul, MN, ("3M") under the trade designation "Imperial Beaded Microfinishing Film", which utilize as the abrasive surface grade 600 25 abrasive particles, clay, and a phenolic resin. While these products have enjoyed much success, the industry is continually seeking improved binder systems.
The abrasives art is devoid of teaching the significance that clay fillers may have on the 30 erodability of binders which include addition polymerized resins. This may be because past experience has revealed that in some instances when addition polymerized resins have been incorporated into abrasive articles, the binder does not sufficiently 35 erode. If the binder does not sufficiently erode, the abrasive surface tends to dull and decrease in performance. It would thus be a significant advance in `- 2~079~
--' the abrasives art if binders incorporating addition polymerized resins would controllably erode.
In accordance with the present invention, erodible abrasive composites have been developed which exhibit a S controlled rate of erosion, thus gradually and controllably exposing new abrasive particles to the ~ -~orkpiece being abraded. As used herein the term "composite" means the abrasive coating which is applied to a backing in coated abrasives, the abrasive coating 10 which is applied to fibers in nonwoven abrasives, or the three dimensional body of a bonded abrasive. The term is not intended herein to be used to denote a conglomerate of individual abrasive grains; these latter are defined as "abrasive agglomerates."
15 Composites within the invention may include agglomerates of individual abrasive grains.
The abrasive composites of the invention are characterized by having abrasive particles dispersed in ~ ~
a binder, the binder including an addition polymerized ~ ~-20 resin having clay particles dispersed therein.
"Binder" means a solidified composition including a cured, gelled or polymerized resin, where "resin"
includes monomeric, oligomeric, and polymeric materials. Curing primarily involves radiation-25 initiated polymerization processes, but can includethermally-initiated polymerization or gelling.
Preferably, all of the abrasive particles are engulfed by the clay particle-containing binder. The term "addition polymerized resin" means a resin that has 30 been at least partially cured, gelled, or polymerized by a free radical or ionic mechanism, preferably in the presence of radiation and a photoinitiator. The terms "polymerized" and "polymerizable" are meant to include both chain growth and crosslinking reactions.
35 "Radiation" includes "non-particle" radiation (such as W radiation and visible radiation, which typically and preferably employ a photoinitiator), and "particle"

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radiation (such as electron beam irradiation, whichdoes not require a photoinitiator).
The inventor herein has discovered that the presence of clay particles results in an abrasive S composite that exhibits a "controlled rate of erosion."
As used herein, this means that the composite erodes to expose new abrasive grains but does not erode at a rate which is unacceptably high for the particular use. It is also to be understood that "controlled rate" does 10 not necessarily mean that the rate is uniform over the life of the article. While difficult to define, controlled erodability is preferred in many abrasive products, particularly in lapping coated abrasives.
The addition of other inorganic particulates to the 15 binder precursor may also contribute to erodability.
However, some of these other inorganic particulates may I result in "too fast" of an erosion rate; while other ! inorganic particulates may result in "too slow" of an erosion rate. Either too fast or too slow of an 1 20 erosion rate results in an abrasive article not having ; an optimum cut rate. It is theorized that the addition of clay to the binder precursor results in a "controlled erosion" binder having an optimum cut rate.
Clays described herein as useful in the invention 25 unfortunately typically absorb W and visible radiation ~ and thus may not allow W or visible light to pass ; through sufficiently to achieve commercially acceptable curing rates. It was thus quite unexpected and ; surprising that the addition polymerizable resins used 30 herein were curable even in the presence of clay.
Preferred abrasive composites in accordance with the invention are those wherein the addition -1 polymerizable resin is selected from the group consisting of ethylenically unsaturated materials and 35 epoxy resins. Preferred ethylenically unsaturated materials include acrylated urethane resins, acrylated epoxy resins, ethylenically unsaturated monomers (such _ 4 _ .7 ~ .

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as styrene, vinyl toluene, divinylbenzene, and the like), aminoplast resins having pendant unsaturated carbonyl groups, isocyanurate resins having at least one pendant acrylate group, isocyanate resins having at 5 least one pendant acrylate group, and the like. It will be understood that mixtures and combinations thereof may be utilized. An especially preferred ethylenically unsaturated material for use in the present invention is the triacrylate of 10 tris(hydroxyethyl) isocyanurate combined with trimethylol propane triacrylate.
The controlled rate of erosion of the composites of the invention is observed under both wet and dry grinding conditions, wet being preferred. "Wet" as 15 used herein refers to application of a liquid, preferably water or other aqueous mixture, to the workpiece during abrasion of the workpiece. Abrasive articles incorporating the erodible abrasive composites and methods of making and using such composites and 20 articles are also presented.
As used herein the term "erodible" refers to the ability of a composite made in accordance with the invention to break down its structure in a controlled manner, for example, by fracture under mechanical 25 grinding forces. A water or other aqueous flood may of course help a binder erode by carrying away broken pieces of binder.
Abrasive composites in accordance with the invention have binders wherein the clay particles have 30 an average particle size ranging from about 0.01 micrometer to about 50 micrometers, more preferably ranging from about 0.1 to about 15 micrometers.
One preferred abrasive composition within the invention includes by weight (dry) from about 20 to 35 about 95 percent abrasive particles, from about 3 to about 78 percent addition polymerized resin, and from about 2 to about 50 percent clay particles.

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The primary aspect of the invention is an abrasive article characterized by an abrasive composite attached to a backing, the abrasive composite comprising the inventive composite above-described. Preferred 5 backings include primed and unprimed polymeric films, cloth, paper, vulcanized fiber, woven articles, and combinations thereof.
Articles also deemed within the invention are those having backings comprising an open, porous, 10 fibrous, lofty, nonwoven substrate. Especially preferred nonwoven backings are those including thermoplastic fibers selected from the group consisting of polyamide, polyester, polypropylene, polyethylene, and combinations thereof. The distinction between 15 coated abrasives and nonwoven abrasives is well known in the art. In the case of a nonwoven abrasive article, the abrasive composite is bonded to the fibers of an open, lofty, porous, fibrous, nonwoven web. In the case of a coated abrasive, such as a lapping 20 abrasive article, the abrasive composite is bonded to at least one surface of a non-porous backing.
Coated abrasive articles exhibiting controlled erosion of its abrasive coating are characterized by (a) a backing having a front and a back surface;
and (b) an abrasive composite attached to at least one of the front or back surfaces, the abrasive composite being the inventivP
abrasive composite previously described.
Preferred are those coated abrasives wherein ~ the addition polymerized resin is selected from those ; used in the inventive abrasive composites previously described. Suitable coated abrasive articles within the invention include those wherein the abrasive 35 composite comprises a make coating which adheres abrasive particles to the backing, and a size coating applied over the abrasive particles. Optional coatings :: .

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include saturant, presize, backsize and supersize coatings, all, some, or none of which may comprise the addition polymerized resins described herein. If none of the optional coatings are comprised of addition 5 polymerized resins, then other resins, such as thermoplastic resins, and thermoset resins, such as phenolic resins, urea-aldehyde resins, and the like, commonly used in coated abrasive manufacturing, may be utilized for those coatings.
Coatable dispersions including clay particles dispersed in a binder precursor, the binder precursor comprising an addition polymerizable resin, are used to make to composites. The term "dispersion" means a binder precursor composition which includes an uncured 15 resin and clay particles, but not abrasive particles.
The clay particles are present in an amount insufficient to prevent curing of the addition polymerizable resin by exposure to radiation energy.
The phrase "an amount insufficient to prevent curing of 20 the addition polymerizable resin by exposure to radiation energy" means that at a given radiation intensity and type of photoinitiator, if used, the amount of clay cannot exceed that amount which would render commercially unfeasible the time needed for 25 curing of the addition polymerizable resin to create a hard, dimensionally stable binder. For this invention, when W curing is used, in order to fully polymerize all ethylenically unsaturated monomer and other monomers present, the W energy level should be at 30 least about 100 to about 1200 milliJoules per cm2, preferably from about 400 to about 700 milliJoules per cm2. Cure conditions may vary with the type of radiation and initiator used, and the amount of clay present. When electron beam irradiation is used, it 35 preferably has a dosage level ranging from about 0.1 to ~; :
210~95a about 10 Mrad, more preferably 1 to 6 Mrad to effect full cure.
Preferred coatable dispersions in accordance with this aspect of the invention are those wherein the 5 weight percentage (dry basis) of clay particles in the composition ranges from about 1 to about 50 weight percent, more preferably ranging from about 5 to about 30 weight percent.
Coatable slurries comprising the inventive 10 dispersions and which further include abrasive particles are particularly preferred. The term "slurry" means a binder precursor composition which includes an uncured resin, abrasive particles, and clay particles. Coatable slurries within the invention 15 having abrasive particles therein typically and preferably comprise by weight (dry basis) between about 20 to about 95 percent abrasive particles, from about 3 to about 78 percent addition polymerizable resin (including photoinitiator if used), and from about 2 to 20 about 50 percent clay particles.
The general method of making the inventive abrasive composites is characterized by a first step of forming a slurry comprising abrasive particles, an addition polymerizable resin, optionally a 25 photoinitiator (depending on the type and energy level of radiation energy utilized), and clay particles. The amount of clay particles is sufficient to render a controlled erosion rate for the binder but insufficient to prevent curing of the addition polymerizable resin 30 by use of radiation energy. The second step is exposing the slurry to radiation energy sufficient to cure the addition polymerizable resin. Methods wherein prior to the exposing step the slurry is applied to a backing are particularly preferred. ~ -1 35 Methods of making a coated abrasive having make ~ -; and size coatings are also described. First, a coatable dispersion of the invention is prepared, which 210795~

is then applied to a backing as a make coating. At this stage, the make coating may optionally be partially cured. Then abrasive particles are applied to the uncured or partially cured make coating, and the 5 make coating exposed to conditions which at least partially cure the addition polymerizable resin, with a size coating then being applied. The last step is `-exposing the make and size coatings to conditions sufficient to fully cure the addition polymerizable 10 resin and size coating. It will be understood that the size coating may comprise other than radiation curable resins, such as phenolic resins. Alternatively, the make coating may comprise a phenolic or other binder resin, with the size coating comprising an addition 15 polymerizable resin, or both make and size coatings could comprise the dispersion of the invention. It should be understood that blends of addition polymerizable resins and other resins may be employed as make and/or size coatings.
A method particularly well suited for making coated abrasive articles, especially lapping abrasive articles, is another aspect of the invention. This method is characterized by the steps of:
1) coating a slurry onto a production tool having 25 a three dimensional pattern, the slurry including an addition polymerizable resin, abrasive particles, and clay particles;
j 2) contacting a substrate having at least one major surface with the slurry so that the slurry wets 30 at least one major surface of the substrate, thus forming a first intermediate article;
3) exposing the slurry to conditions sufficient to at least partially cure the addition polymerizable resin to form a second intermediate article; and 4) removing the second intermediate article from the productioD tool, yielding an abrasive article.

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An alternative to this latter method is characterized by the steps of:
1) contacting a substrate having at least one major surface with a slurry such that the slurry wets 5 at least one surface to form a first intermediate article, the slurry including an addition polymerizable resin, abrasive particles, and clay particles;
2) contacting the slurry of the first intermediate article to a production tool having a three dimensional 10 pattern;
3) exposing the slurry to conditions sufficient to at least partially cure the addition polymerizable resin to form a second intermediate article; and 4) removing the second intermediate article from 15 the production tool, yielding an abrasive article.
Preferred "conditions" referred to in the third steps of the two immediately preceding inventive methods are radiation energy, particularly W
radiation. In order to carry out these methods, it is 20 necessary that either the substrate or the production tool be transparent to the type of radiation used.
Production tools having three dimensional patterns are described generally in U.S. Pat. No. 5,152,917.
During the manufacture of the abrasive articles of 25 the invention, the binder precursors are exposed to energy sufficient to cure the addition polymerizable resins and other resins which may be present. If non-particle (e.g., ultraviolet, visible) radiation is used, a photoinitiator is preferred to generate free 30 radicals. Alternatively, an ionic (preferably ~ ;
cationic) source could be used. This free radical source or ionic source then initiates the polymerization of the addition polymerizable resin.
Electron beam curing typically does not require a 35 photoinitiator, but photoinitiators may be used to accelerate cure. In all addition polymerization conditions, heat may expedite the curing process.

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_ It is theorized that various clays induce cured addition polymerized resins to be more erodible than the resin would otherwise be absent the clay. This phenomenon causes binders incorporating addition S polymerized resins and clay to controllably erode, allowing worn or dulled abrasive particles to be broken away from the abrasive composite and new abrasive particles to be exposed. Newly exposed abrasive particles are typically more efficient in cutting than 10 dull abrasive particles. The addition of clay results in a "controlled erosion" rate which results in an optimum cut rate. If the erosion rate is too slow, then the dulled abrasive particles are not broken away fast enough; this leads to reduced performance. If the 15 erosion rate is too fast, then the abrasive particles are broken away before their full utilization; this also results in a less optimum use of the abrasive article.
Clays may be generally described as hydrated 20 silicates of aluminum, magnesium, or iron. They usually exhibit a sheet-like, platy structure, typically consist of very fine particles, and usually contain impurities such as quartz, carbonates, or sulfides which are nonclay-like.
2 Clays useful in the invention may be broadly classified as crystalline or amorphous. Amorphous clays belong to the allophane group, while crystalline clays belong to the phyllosilicate group. The phyllosilicate group is further divided into planar 30 hydrous and nonplanar hydrous minerals. Examples of planar hydrous clay minerals are kaolinite, talc, pyrophyllite, saponite, montmorillonite, muscovite, ;
clintonite, and clinochlore. Examples of nonplanar -~
hydrous clay minerals are antigorite, greenalite, 35 ganophylite, bannisterite, and chrysotile. A recent classification of crystalline clay minerals by the Clay Minerals Society Nomenclature Committee may b- found in 21079~
Clays and Clay Minerals, Vol. 39, No. 3, pp. 333-335 (1991). Note that while many of these clay minerals are the primary ingredients of clays they may also be present in large "rock" particles and would not then 5 typically be considered clays.
Crystalline clays may be transformed into amorphous clays by heating and driving off water of hydration (i.e., chemically bound water), and it may be that an original amount of crystalline clay may 10 transform to amorphous clay during grinding operations.
Three particularly preferred clays for use in the invention are kaolin, calcined (amorphous) kaolin, and montmorillonite (bentonite).
Although clay particles are platy, a particle 15 size range can be useful to describe them. For the purposes of this invention clay particles preferably range in average particle size between about 0.01 micrometer to about 50 micrometers, more preferably between about 0.1 micrometer to about 15 micrometers, 20 and particularly preferably between about 0.1 micrometer to about 5 micrometers. The average particle size of the clay particles may be less than, greater than, or equal to the average particle size of the abrasive particles. In some instances it may be 25 preferred that the average particle size of the clay particles be less than the average particle size of the abrasive particles so that the clay particle-containing binder precursor can engulf the abrasive particles without substantial void space between the clay 30 particle-containing binder and abrasive particles.
Coatable binder precursor compositions within the invention include dispersions and slurries, as previously defined. The dispersions and slurries contain an amount of clay sufficient to render the 35 cured binder more erodible but insufficient to prevent curing of the addition polymerizable resin by exposure to radiation (and a photoinitiator if needed). In other 2 ~ 5 ~ -, words, using a given radiation energy (and photoinitiator, if required), the amount of clay preferably does not exceed that amount which would render the time required for curing of the addition 5 polymerizable resin to create a hard, dimensionally stable binder commercially unfeasible. Generally, as the weight ratio of clay to resin increases, the "depth of cure" decreases, where depth of cure is measured from the exposed surface of the binder precursor in a 10 direction opposite the point of oriyin of the radiation source.
Abrasive composites within the invention, as stated previously, comprise abrasive particles dispersed in a binder, the binder comprising an 15 addition polymerizable resin having clay particles dispersed therein. Preferably, all of the abrasive particles are engulfed (i.e., totally surrounded~ by the clay particle-containing binder. However, in the case when make and siæe coatings are utilized in coated 20 abrasives, the abrasive particles are adhered to the backing by the make resin and supported further by the size resin. Either the make coating, size coating, or both may comprise addition polymerizable resin having clay particles dispersed therein.
Addition polymerizable resins useful in the practice of the invention are those resins capable of being cured by the exposure to radiation energy, either in the presence of a photoinitiator or without an initiator. Useful resins include those curable by ! 30 particle radiation, non-particle radiation, or both.
f Non-particle radiation includes W radiation and ~ visible light, while the most commonly used particle i radiation used is electron beam irradiation. A
I combination of particle and non-particle radiation 35 energy sources may be used, but non-particle radiation energy sources, particularly W and visible light energy sources, are presently preferred.

~, 21079~
Electron beam irradiation preferably has a dosage level ranging from about 0.1 to about 10 Mrad, more preferably 1 to 6 Mrad. W radiation is non-particle radiation having wavelength ranging from about 200 to 5 about 700 nanometers, preferably from about 250 to about 400 nanometers. Visible radiation is non-particle radiation having a wavelength ranging from about 400 to about 800 nanometers, preferably ranging from about 400 to about 550 nanometers.
When a photoinitiator is exposed to non-particle radiation such as ultraviolet radiation or visible light, the photoinitiator generates a free radicAl or an ion. This free radical or ion initiates the polymerization of addition polymerizable resins.
Examples of addition polymerizable resins preferred for use in the present invention and that are capable of being polymerized by non-particle radiation include acrylated monomers, oligomers, and polymers (such as acrylated urethane resins and acrylated epoxy 20 resins); ethylenically unsaturated monomers (such as styrene, divinylbenzene, vinyl toluene, and the like);
aminoplast resins having pendant unsaturated carbonyl groups, and the like, such as those having at least 1.1 pendant alpha, beta-unsaturated carbonyl groups per - -25 molecule or oligomer, which are further described in ~ U.S. Pat. No. 4,903,440; isocyanurate resins having at ¦ least one pendant acrylate group, and the like, which are described in U.S. Pat. No. 4,652,275 ~such as the triacrylate of tris(hydroxyethyl) isocyanurate);
1 30 isocyanate resins having at least one pendant acrylate P group; epoxy resins; and mixtures and combinations !j thereof. The term "acrylated" is meant to include monoacrylated, diacrylated, and multiacylated monomers, oligomers, and polymers, and monomethacrylated, 35 dimethacrylated, and multimethacrylated monomers, } oligomers, and polymers. "Oligomer" has its generally 3 accepted meaning as a material comprised of 2 to 5 .

identical monomer units. Another generally accepted definition is that an oligomer is 'a polymer whose properties change with the addition or removal of one or a few repeating units. The properties of a true 5 polymer do not change markedly with such modification.
It is noteworthy to mention that monomers which are solids at room temperature may be used if dissolved in a suitable diluent. This is the case with the triacrylate of tris(hydroxyethyl) isocyanurate 10 ("TATHEIC"), one particularly preferred resin, which is a solid at room temperature. When this monomer is used, the "polymerizable resin" for which viscosity reduction is attained includes the diluent, which may or may not be reactive with the monomer, but preferably 15 is reactive with the monomer (and is therefore considered another monomer). One preferred diluent for room temperature solid acrylated monomers is trimethylol propane triacrylate ("TMPTA"); however, diluents such as these are more correctly referred to 20 as reactive diluents when the polymerizable resin is already liquid at room temperature (i.e., about 25C).
When TATHEIC is used, the combination of TATHEIC/TMPTA
is considered as the polymerizable resin in the ~-I slurries and dispersions of the invention. The weight ¦ 25 ratio of TATHEIC/TMPTA preferably ranges from about 1:2 I to about 2:1, more preferably from about 1:1.7 to about ¦ 1.7:1, most preferably 1:1. It should be noted that ¦ TATHEIC or TMPTA may be used alone as the addition ¦ polymerizable resin, with only a slight decrease in ¦ 30 grinding performance being noticeable.
Acrylated urethane oligomer resins are preferably acrylate esters of hydroxy-terminated, isocyanate-extended polyester or polyether polyols transesterified with low molecular weight acrylates (such as 2-35 hydroxyethyl acrylate). The number average molecular ~ weight of preferred acrylated urethane oligomer resins t rangesfifrom about 300 to about 10,000, more preferably ~ - 15 -i, /
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from about 400 to about 7,000. Examples of commercially available acrylated urethane oligomer resins are those marketed under the trade designations "WITHANE 782" (available from Morton Thiokol Chemical) 5 and "CMD 6600", "CMD 8400", and "CMD 8805" (available from Radcure Specialties).
Epoxy resins have an oxirane ring and are polymerized by ring opening. Such epoxide resins include monomeric and oligomeric epoxy resinsO These 10 resins can vary greatly in the nature of their backbones and substituent groups. For example, the backbone may be of any type normally associated with epoxy resins and substituent groups thereon can be any group free of an active hydrogen atom that is reactive 15 with an oxirane ring at room temperature.
Representative examples of acceptable substituent groups include halogens, ester groups, ether groups, sulfonate groups, siloxane groups, nitro groups and phosphate groups. Examples of some preferred epoxy 20 resins include 2,2-bis[4-(2,3-epoxypropoxy)-phenyl)propane] (a diglycidyl ether of bisphenol A) and commercially available under the trade designations "Epon 828", "Epon 1004" and "Epon 1001F" available from Shell Chemical Co., and "DER-331", "DER-332" and "DER-25 334" available from Dow Chemical Co. Other suitableepoxy resins include glycidyl ethers of phenol formaldehyde novolak resins (e.g. those known under the trade designations "DEN-431" and "DEN-438" available from Dow Chemical Co.). Epoxy resins useful in the 30 invention can polymerize via a cationic mechanism with the addition of an appropriate photoinitiator (5) .
These resins are further described in U.S. Pat. No.
4,318~766, incorporated herein by reference.
Acrylated epoxy oligomer resins are acrylate 35 esters of epoxy resins, such as the diacrylate esters of bisphenol-A epoxy resin. Examples of commercially available acrylated epoxy oligomer resins include those f .,.. ~,.......................... . .

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known under the trade designations "CMD 3500", "CMD
3600", and "CMD 3700", available from Radcure Specialties.
Other addition polymerizable resins useful in the 5 invention include those that contain atoms of carbon and hydrogen, and optionally oxygen, nitrogen and the halogens. Oxygen or nitrogen atoms or both are generally present in ether, ester, urethane, amide, and urea linkages.
Diluents may also be used in the slurries and dispersions of the invention. As used herein the term "diluent" connotes a low molecular weight (preferably less than about 500) organic compound that may or may not decrease viscosity of compositions to which they 15 are added. "Reactive" diluents are diluents which I react with the resin and remain in the cured binder in j a chemically bound state, while "inert" diluents are diluents that do not react with the resin. Both reactive and inert diluents may be utilized in the 20 invention.
Preferred reactive diluents are acrylates having a molecular weight ranging from about 100 to about 500, including ethylene glycol diacrylate, ethylene glycol dimethacrylate, hydroxypropyl methacrylate, 25 tetrahydrofurfuryl acrylate, hydroxyethyl methacrylate, hexanediol diacrylate, triethylene glycol diacrylate, trimethylol propane triacrylate, glycerol triacrylate, ¦ pentaerthyitol triacrylate, pentaerythritol trimethacrylate, pentaerythritol tetraacrylate, 3 30 pentaerythritol tetramethacrylate, and the like.
Other useful reactive diluents include methacrylates such as methyl methacrylate and ethyl methacrylate; monoallyl, polyallyl, and polymethallyl 3 esters and amides of carboxylic acids (such as diallyl 35 phthalate, diallyl adipate, and N,N-diallyladipamide);
~ tris(2-acryloyl-oxyethyl)isocyanurate, 1,3,5-tri(2-`3 methacryloxyethyl)-s-triazine, acrylamide, ,, :~, 21079~
methylacrylamide, N-methylacrylamide, N,N-dimethylacrylamide, N-vinylpyrrolidone, and N-vinylpiperidone.
Addition polymerizable resins which are non-5 particle radiation curable preferably include aphotoinitiator. Examples of photoinitiators that when exposed to ultraviolet light generate a free radical include organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acryl halides, 10 hydrozones, mercapto compounds, pyrylium compounds, triacrylimidazoles, bisimidazoles, chloroalkytria~ines, benzoin ethers, benzil ketals, thioxanthones, and acetophenone derivatives, and mixtures thereof.
Examples of photoinitiators that when exposed to -15 visible radiation generate a free radical are described in U.S. Pat. No. 4,735,632. -~
Cationic photoinitiators generate an acid source which initiates the polymerization of some addition polymerizable resins, such as epoxy resins. Cationic 20 photoinitiators can include a salt having an onium cation and a halogen containing complex anion of a ¦ metal or metalloid. Other useful cationic ~ photoinitiators include salts of organometallic complex I cations and halogen-containing complex anions of a ¦ 25 metal or metalloid, which are further described in U.S.
I Pat. No. 4,751,138. Still other useful cationic ¦ photoinitiators are organometallic salts and onium ¦ salts, described in U.S. Pat. No. 4,985,340, and European Patent Applications 306,161 and 306,162, both 30 published March 8, 1989. Yet other useful cationic photoinitiators include ionic salts of an organometallic complex in which the metal is selected from the elements of Periodic Group IVB, VB, VIB, VIIB
and VIIIB, such salts being described in European 35 Patent Application 109,581 tpublished May 30, 1984).
Photoinitiators, when used, preferably comprise from about 0.1 to about 10 weight percent of the .~

` ~079~5 dispersion or slurry, more preferably form about 1 to about 5 weight percent.
Abrasive articles are defined herein as a backing having the abrasive composite of the invention adhered 5 thereto, although the term "abrasive articles" is intended to include the abrasive composite itself (i.e., without a backing).
Nonwoven abrasive articles are well known in the art and generally illustrated ir. U.S. Pat. No.
10 2,958,593. In general they comprise open, lofty, webs of fibers bonded together at points where they contact by a binder.
In the case of coated abrasives, such as lapping abrasive articles, the abrasive composite of the 15 invention is bonded to at least one surface of a backing. In the case of a lapping coated abrasive, the backing is preferably a continuous (i.e., non-porous) polymeric film, preferably primed with an ethylene acrylic acid copolymer. Examples of typical and 20 preferable backing materials utilized in lapping abrasive articles are polymeric films having melting temperatures able to withstand the frictional heat generated during abrasion (e.g., polyester, and the like), primed polymeric film, cloth, paper and other 25 nonwovens, and treated versions thereof and combinations thereof. Vulcanized fiber backings may also be useful in coated abrasives.
Coated abrasives in accordance with the invention made using make and size coatings have at least one of 30 the make and size coatings formed from a dispersion comprising an addition polymerizable resin, an optional photoinitiator, and a plurality of clay particles dispersed therein. The addition polymerizable resin, photoinitiator, and clay particles for these 35 embodiments are the same as previously described.
Additionally, the dispersions of the invention may contain other optional additives. These additives J~i'" '. ~

21~7~5 include fillers tincluding grinding aids), fibers, lubricants, wetting agents, surfactants, pigments, dyes, coupling agents, plasticizers and suspending agents. In some cases there may be a beneficial 5 synergistic effect on abrading performance when clay particles are employed with other optional fillers, such as calcium carbonate. The amounts of these optional materials are selected to provide the properties desired. The dispersions may also include 10 either organic solvent and/or water as needed.
As previously stated, the make coating and/or size coating may comprise the dispersion of the invention.
Optionally, the dispersion can be used as a supersize coating, i.e., the adhesive coating over the size 15 coating, or as a backing substrate treatment or coating. In particular, the backing may have a saturant coating which saturates the substrate, a backsize coat which is present on the back side of the backing opposite the abrasive particles, or as a 20 presize coating which is present on the front side of the backing, between the backing and the make coating.
However, as the primary intent is to have the composite of the invention controllably erode during the abrading process, the advantages of using the dispersions of the 25 invention in these optional coatings are lessened or not exhibited. Thus, the dispersion of the invention comprising an addition polymerized resin and clay particles is preferably the precursor to at least one of the make or size coatings to ef~ect the advantage of 30 presenting new abrasive particles to the workpiece.
The other binder coatings can be any of the traditional adhesive resins used in abrasive articles, such as phenolic resins, aminoplast resins, urethane resins, lattices, epoxy resins, urea-aldehyde resins, 35 isocyanurate resins, and mixtures thereof.
Depending upon the particular traditional resin, the binder precursor containing the traditional resin .

2107~5 may further include a catalyst or curing agent. The catalyst and/or curing agent will either help to initiate and/or accelerate the polymerization process.
Additionally, the traditional binder coatings may 5 also include other additives well known in the coated abrasive art. These additives include fillers (including grinding aids), fibers, lubricants, wetting agents, surfactants, pigments, dyes, coupling agents, plasticizers and suspending agents. The amounts of 10 these materials are selected to provide the properties desired.
The choice of backing material will depend on the intended application of the abrasive article. The strength of the backing should be sufficient to resist 15 tearing or other damage in use, and the thickness and smoothness of the backing should allow achievement of the product thickness and smoothness desired for the intended application. The adhesion of the inventive slurry or dispersion to the backing should also be 20 sufficient to prevent significant shedding of individual abrasive particles or the abrasive coating during normal use. In some applications it is also preferable that the backing be waterproof. The thickness of the backing should be sufficient to 25 provide the strength desired for the intended application; nevertheless, it should not be so thick as to affect the desired flexibility in the coated abrasive product. It is preferred that the backing be a polymeric film, such as polyester film, for lapping 30 coated abrasives, and that the film be primed with a material, such as ethylene acrylic acid copolymer, to promote adhesion of the inventive slurry or dispersion and resulting abrasive composite to the film. It is also preferred that the backing be transparent to 35 ultraviolet or visible radiation if a method involving a non-transparent production tool having a three .
- 2la7~
dimensional pattern thereon is used, as discussed herein below. -In the case of a woven backing, it is sometimes preferable to fill the interstices of the backing with 5 at least one coating before the application of the inventive slurry or dispersion. Coatings used for this purpose are called saturant, back or presize coatings, depending on how and to what surface of the backing the -coating is applied.
The backing may comprise a laminate of backings made by laminating two or more plies of either similar or dissimilar bac~ing materials. For example, the backing can be laminated to a stiffer, more rigid substrate, such as a metal plate, to produce a coated 15 abrasive article having an abrasive coating supported on a rigid substrate.
The surface of the backing not containing the abrasive coating may also contain a pressure-sensitive adhesive or a hook and loop type attachment system so 20 that the abrasive article can be secured to a back-up pad. Examples of pressure-sensitive adhesives suitable for this purpose include rubber-based adhesives, acrylate-based adhesives, and silicone-based adhesives.
Individual abrasive particles may be selected from 25 those commonly used in the abrasive art, however, the abrasive particles (size and composition) will be chosen with the application of the abrasive article in mind. In choosing an appropriate abrasive particle, characteristics such as hardness, compatibility with 30 the intended workpiece, particle size, reactivity with the workpiece, as well as heat conductivity may be considered.
The composition of abrasive particles useful in the invention can be divided into two classes: natural 35 abrasives and manufactured abrasivss. Examples of natural abrasives include: diamond, corundum, emery, garnet, buhrstone, chert, quartz, sandstone, 2~ 0~5~
chalcedony, flint, quartzite, silica, feldspar, pumice and talc. Examples of manufactured abrasives include:
boron carbide, cubic boron nitride, fused alumina, ceramic aluminum oxide, heat treated aluminum oxide, 5 alumina zirconia, glass, silicon carbide, iron oxides, tantalum carbide, cerium oxide, tin oxide, titanium carbide, synthetic diamond, manganese dioxide, zirconium oxide, and silicon nitride.
Abrasive particles useful in the invention 10 typically and preferably have a particle size ranging from about 0.1 micrometer to about 1500 micrometers, more preferably ranging from about 0.1 micrometer to about 1300 micrometers. The abrasive particles preferably have an average particle size ranging from 15 about 0.1 micrometer to about 700 micrometers, more preferably ranging from about 1 to about 150 micrometers, particularly preferably from about 1 to about 80 micrometers. It is preferred that abrasive particles used in the invention have a Moh's hardness 20 of at least ~, more preferably above 9; however, for j specific applications, softer particles may be used.
¦ Although not required, when curing by use of radiation, curing appears to be faster if the refractive index of the abrasive particles matches or 25 is close to the refractive index of the particular resin being used. The preferred abrasive particle is white aluminum oxide due to its relatively non-ultraviolet radiation absorbance property.
The abrasive composite of the invention is formed 30 from a slurry that includes a plurality of abrasive particles, an addition polymerizable resin, a photoinitiator (if the resin is non-particle radiation j curable), and a plurality of clay particles. Methods I of making the abrasive composite may be described as 35 comprising the steps of:

.

2107~

a. preparing a slurry by combining:
1. a plurality of abrasive particles; ~
2. an addition polymerizable resin; -3. a photoinitiator, if needed;
4. a plurality of clay particles; and 5. optional ingredients such as grinding aids; and b. exposing the slurry to radiation energy sufficient to cure the resin.
In step (a), it is preferred that the radiation curable resin and photoinitiator, if required, are first mixed together, then the abrasive and clay particles. It is preferred that the abrasive particles and clay particles are uniformly dispersed throughout 15 the resins. In some instances a high shear mixer is employed to achieve a uniform suspension. ~ethods wherein the slurry is first applied to a substrate backing are alternate methods within the invention.
For a nonwoven abrasive article, the slurry is 20 then applied to a three-dimensional nonwoven substrate.
Typically, this is accomplished by spray coating or roll coating. For a lapping coated abrasive article, the slurry is applied to the front side of a backing by any conventional means such as spray coating, roll 25 coating, die coating or knife coating.
Next, the slurry is exposed to a radiation source, preferably W or visible light, to cure the resin. The amount of energy required ~given the same backing and tooling) is primarily dependent upon the resinous 30 adhesive chemistry and secondarily on the thickness of the binder precursor. Typically the amount of time the binder precursor is exposed to the radiation source can range from about 0.1 to 100 seconds, but is preferably less than 5 seconds.
One particularly preferred method of making a lapping abrasive is described in the assignee's U.S.
Pat. No. 5,152,917 (Pieper et al.). In these methods, ~$

` ~ 2~079~
the resulting solidified slurry or abrasive composite will have the inverse pattern of a production tool. By at least partially curing or solidifying the slurry on a production tool, the abrasive composite has a precise 5 and predetermined pattern. The addition polymerizable resin can be further solidified or cured after the partially cured article is taken off of the production tool. The pattern of the production tool may be treated with a release agent, such as a silicone, to 10 ease removal of the article.
It is preferred that the slurry be heated prior to entering the production tool, typically at a temperature ranging from about 40JC to 90C. When the slurry is heated it flows more readily into the 15 cavities of the production tool three dimensional surface, thereby minimizing imperfections. The viscosity of the slurry is preferably closely controlled for several reasons. For example, if the ~ slurry viscosity is too high, it will be difficult to ¦ 20 apply the slurry to the production tool.
The production tool can be a belt, a sheet, a coating roll, a sleeve mounted on a coating roll, or a die. It i~ preferred that the production tool be a coating roll. Typically, a coating roll has a diameter 25 between about 25 cm and 45 cm and is constructed of a rigid material, such as metal. The production tool, once mounted on a coating machine, may be powered by a power-driven motor.
As previously noted, the production tool has a 30 predetermined three dimensional pattern or array of at least one specified shape on the surface thereof, which is the inverse of the pattern of the abrasive composite of the article of the invention. Although not a critical aspect of the present invention, the three 35 dimensional pattern of the production tool preferably comprises an array of asymmetric pyramids, as detailed ~, '.'.',.'.,' ' ' :- ' :

~ i."' . , ' , , ' , - ', .

' 2la7s~
in FIGs. 6, 7, and 18 of the previously men~ioned Pieper et al. patent.
Production tools for the process can be prepared from metal, e.g., nickel, although plastic tools can 5 also be used. A production tool made of metal can be fabricated by engraving, hobbing, assembly as a bundle a plurality of metal parts machined in the desired configuration, or other mechanical means, or by electroforming. The preferred method is by diamond 10 turning. These techniques are further described in the Encyclopedia of Polvmer Science and Technology, Vol. 8, John Wiley & Sons, Inc. (1968), pp. 651-665, and U.S.
Pat. No. 3,689,346, column 7, lines 30 to 55.
In some instances, a plastic production tool can 15 be replicated from an original metal tool. The advantages of plastic tools as compared with metal tools are cost and the ability to use non-transparent backings for abrasive articles. The use of a non-transparent backing requires that the radiation is 20 transmitted through the transparent tooling. A
thermoplastic resin, such as polypropylene, can be embossed onto the metal tool at its melting temperature and then quenched to give a thermoplastic inverse replica of the metal tool. This plastic replica can 25 then be utilized as the production tool.
For addition polymerizable resins initiated by radiation energy, it is preferred that the production tool be heated, typically in the range of 30C to 140C, to provide for easier processing and release of 30 the abrasive article. Of course, heating should be limited in the case of plastic transparent tooling to avoid distortion of the pattern and decrease the longevity of the plastic tooling.
Methods of making coated abrasive articles having 35 make and size coatings, one of which comprises addition polymerizable resin and clay, were described previously. Illustrated below is an example of how to 21~9~

make a coated abrasive article having various optional coatings.
As a first optional coating, a substrate may be saturated with a saturant coating precursor by any 5 conventional technique such as dip coating or roll coating.
After the saturant coat is applied, optional backsize and/or presize coating precursors are applied by a technique such as roll coating, die coating, or lO knife coating. The make coating precursor is applied over the optional presize. Optionally, the make coating is then partially cured. The abrasive particles are then projected into the make coating precursor. Preferably, the abrasive particles are 15 projected by an electrostatic coating process, although drop coating may suffice. The make coating is then exposed to conditions sufficient to at least partially cure the make coating. Then a size coating precursor is applied over the abrasive grains by any conventional 20 technique. Finally, if desired, a supersize coating precursor is applied over the size coating by any one of the previously mentioned techniques.
For those coatings which include addition polymerizable resin, those coatings are exposed to 25 radiation energy to initiate polymerization of the resin. If the other coatings contain thermosetting binder precursors, they may be solidified by application of heat. In addition, it is believed that heating will accelerate radiation polymerization, so 30 that combinations of various energy sources may be used with good results. The choice of the energy source utilized will depend upon the chemistry of the resins employed, the thickness of the coating, the thickness of the backing if radiation must pass through it, the 35 type and amount of abrasive and clay particles, and the like.

21~7 ':
-All coating precursors are at least either partially dried or partially cured such that each coating is dry to the touch before the next coating is applied. Alternatively the coatings can be fully cured 5 before the next coating is applied. After the last coating is applied, the remaining partially cured coatings are subject to conditions which substantially fully cure the coatings.
The following test procedures were used throughout 10 the examples.
Disc Tast Procedure I
Coated abrasive articles for each example were converted into 10.2 cm diameter discs and secured to a foam back-up pad by means of a pressure sensitive 15 adhesive. The coated abrasive disc and back-up pad assembly was installed on a Schiefer testing machine, and the coated abxasive disc was used to abrade a polymethyl methacrylate polymer workpiece using a force of 4.5 kg. All of the testing was done using a water 20 flood. The amount of workpiece abraded or cut was measured for every 500 cycles. The cut values were listed as a percent of the Comparative Example, i.e., the amount that the example cut divided by the amount that the comparative example cut multiplied by 100%.
25 Additionally in some instances, the surface finish (Ra and Rz~ generated by the abrasive article on the workpiece was measured. Ra is the arithmetic average of the scratch size in microinches. Rz was the mean of the five consecutive individual roughness measurements.
~ 30 The surface finish was measured using a profilometer 7 known under the trade designation "Perthen", built by Perthometer MYB. The ideal coated abrasive has a high cut rate and a low surface finish value.
Disc Test Procedure II
Disc Test Procedure II was the same as Disc Test Procedure I, except that the workpiece was cellulose acetate butyrate polymer and the testing was done dry.

i :-` 2~0795~
Te~t Procedure III
Each coated abrasive article to be tested was converted into a 5.7 cm by 22.9 cm rectangular sheet.
The abrasive article was secured using clips to a 4.54 5 kg metal block back up pad. The coated abrasive surface contacting the workpiece was 5.7 cm by 15.1 cm.
The workpiece was a 45 cm by 77 cm metal plate which was coated with a urethane primer of a type commonly used in the automotive paint industry. During sanding, 10 the surface of the workpiece was flooded with water.
The abrasive article/back up pad was moved 90 strokes against the workpiece to sand the urethane primer. A
stroke was the movement of the operator's hand in a straight line back and forth motion. The cut, i.e. the 15 amount in micrometers of primer xemoved, was measured after 90 strokes. The paint thickness was measured with a measurement tool known under the trade designation "Elcometer", sold by Elcometer Instruments Limited, Manchester, England. The surface finish Ra, 20 i.e., the surface finish of the primer abraded, was measured after 10 cycles. The surface finish was measured using the same profilometer as in Disc Test Procedure I.
The following non-limiting examples will further 25 illustrate the invention. All parts, percentages, ratios, etc., in the examples are by weight unless otherwise indicated.
Examples The following materials were used in the Examples.
30 TATHEIC denotes a triacrylate of tris(hydroxyethyl) isocyanurate PHl denotes 2,2-dimethoxy-1-2-diphenyl-1-ethanone, commercially available from Ciba Geigy Company under the trade designation "Irgacure 651"
TMPTA denotes trimethylol propane triacrylate s,;.

` ~ 210~9~
: WAO denotes white fused aluminum oxide abrasive particles ASP denotes clay particles having an average particle size of about 2 micrometers, commercially available from the Engelhard Company of Edison, NJ. under the trade designation "ASP 600"
PC denotes clay particles having an average particle size of about 3 micrometers, commercially available from R.T. Vanderbilt of Norwalk, CT~ under the trade designation "Peerless #4"
CA denotes gamma-methacryloxypropyltrimethoxy silane, a coupling agent commercially available from the Union Carbide Corporation under the trade designation "A-174"
CS denotes a natural cryolite available from Washington Mills Abrasives having average particle size of about 3 micrometers 20 CC denotes calcium carbonate filler having an average particle size of about 15 micrometers CMS denotes a calcium metasilicate filler treated with an amino silane coupling agent commercially available from the Nyco Company 25 Exa~pla~ I and 2 and Csmparativ~ Example~ A ~nd B -This set of examples compared various abrasive article constructions. The abrasive articles were tested according to Disc Test Procedure I and the test results can be found in Tables 2 and 3.
The abrasive articles of Examples 1 and 2 and Comparative Example A were made according to the teaching of U.S. Pat. No. 5,152,917. First, a slurry was prepared by thoroughly mixing the following :
materials listed in Table 1. The addition 35 polymerizable resin was a mixture of TATHEIC/TMPTA/PHl at a ratio of 50/50/2. The white aluminum oxide abrasive particles had an average particle size of 40 ~ -` . 21079~5 .
micrometers. The slurry was coated onto a nickel production tool having an array of pyramids such that the abrasive slurry filled the recesses between pyramids. The pyramidal pattern was substantially 5 identical to that illustrated in FIGs. 6, 7 and 18 of the previously incorporated Pieper et al. patent. The pattern was asymmetric, with one base width being about 360 micrometers, while another base width was about 400 micrometers. The pyramid height was about 180 10 micrometers.
Next, a 102 micrometer thick polyester film substrate was pressed against the acrylic production tool by means of a plastic squeegie and the abrasive slurry wetted the front surface of the polyester film.
15 The front surface of the polyester film contained an ethylene acrylic acid copolymer primer.
W light was then transmitted through the polyester film and into the slurry, thus initiating the polymerization of the resin. This was carried out 20 using a W curing unit available from Radiation Polymer Company, which consisted of a UV processor model number QC-1202A/NSPL, and two 30.5 cm W metal end mercury lamps, Type H, made by Aetek International. As ~measured using a W curing radiometer which integrated ¦25 at 365 nanometers, the dosage used was between 170-260 milliJoules/cm2 for each pass. Four passes were used.
This dosage of W light resulted in the sl~rry being transformed into an abrasive composite adhered to the polyester film substrate.
Next, the polyester film/abrasive composite construction was separated from the production tool to yield an abrasive article.
The abrasive article for Comparative Example B was a grade 320 (34 micrometer average mineral particle 35 diameter) abrasive grain-containing A weight paper coated abrasive known under the trade designation ., "." : : :
~,;, .

.,.,.,.. , , . , ~ ,, . ~.. .. . . ..

` ` 21079~5 "Three-Mite ~etordry" commercially available from the 3M Company, St. Paul, MN.
Table 1 Abr~ive 81urry Formulations Example Resin WAO ASP CA
-Table 2 Disc Test Procedure I
Cut Values as a Peroent of Comparativ~ Example B
lOExample 500 1000 1500 2000 cycles cycles cycles cycles 1 102.1 105.3 109.0 115.0 2 tOl.6 105.5 109.2 115.1 A 63.1 66.4 69.6 74.8 B 100.0 100.0 lOO.O 100.0 15Table 3 Disc Te~t Pro~edure I
8urf~ce Fini~h Data ;
Example 500 cycles 2000 cycles ~ -Ra Rz Ra Rz ~
: -::
1 24.3 178 21.3 159 2 24.0 174 21.0 144 A 17.3 122 16.7 134 B 25.0 166 21.0 157 It can be concluded that the addition of the clay particles increased the initial cut from 63 to 102~ of the comparative example. A controlled abrasive 25 composite breakdown was seen even under this relatively low pressure test. Comparative Example A did not appear to break down at all.

` 2107955 Examples 3-5 and Comparative E~amples B-G
The abrasive articles for Examples 3 through 5 and Comparative Examples C through G were made in the same manner as explained in Example 1 except that different 5 slurries were employed. The compositions of these slurries can be found in Table 4. The resin and the abrasive particles were the same as Example 1. The filler column refers to the amount and type of an inorganic particulate added to the slurry in each 10 instance. The abrasive articles made in this set of examples were tested according to Test Procedures I-III
and the test results can be found in Tables 5 through 8.

Table 4 Abrnsive Blurry Formulations Example Resin WAO Filler CA

~, F 20 70 10 CC
' G 25 70 5 CMS
~5 ., *:~ :

` `- 21~795~
Table 5 Diso Test Procodure I
Cut Value~ ~s a Perc~nt of Co~parative Exa~ple B
Example 500 1000 1500 2000 cycles cyclescycles cycles -3 92.5 100.6 105.7 110.9 4 91.9 98.4 103.1 107.7 C 72.6 79.1 83.1 87.5 E 68.4 75.7 80.2 84.8 G 71.8 79.7 84.5 89.6 B 100.0 100.0 100.0 100.0 Table 6 DisG Test Procedure I
8urface Flni~h D~t~
Example 500 cycles 2000 cycles Ra Rz Ra Rz 3 23.7 172 20 146 4 23.3 170 21 148 C 22.3 162 18 137 E 20.0 150 18 140 G 20.3 147 17 123 ~, B 25.7 179 20 142 d ., '~ .

2107~5 ~abl~ 7 Disc Te~t Procedure II
Cut Value~ aq a Percent of Comparative Example B
Example 500 cycles 1000 cycles 3 84.2 108.9 4 102.0 132.3 C 108.7 135.8 E 97.0 115.7 G 97.8 128.4 B 100.0 100.0 T~ble 8 Te~t Pro~edure III
Cut Valu~s as ~ Percant of Comp~rativ~ Example B
Example CutRa Rz ___ 3 .72.7 118.0 550.0 15 4 95.7 35.7 239.0 C 52.8 --- --- . -E 71.0 27.0 203.0 G 72.3 35.7 252.0 ~ -B 100.0 38.0 249.0 Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not to be unduly limited to the 25 illustrative embodiments set forth herein.

Claims (7)

1. An abrasive article characterized by an abrasive composite, the composite attached to a backing, the composite having a controlled rate of erosion and comprising abrasive particles dispersed in a binder, the binder including an addition polymerized resin having clay particles dispersed therein.

2. An abrasive article in accordance with claim 1 further characterized by said backing being selected from the group consisting of polymeric film, cloth, paper, and vulcanized fiber.

3. An abrasive article in accordance with claim 1 further characterized by the addition polymerized resin being derived from uncured resins selected from the group consisting of ethylenically unsaturated resins and epoxy resins.

4. An abrasive article in accordance with claim 3 further characterized by the ethylenically unsaturated resin being selected from the group consisting of acrylated urethane resins, styrene, divinylbenzene, vinyl toluene, aminoplast resins having pendant unsaturated carbonyl groups, isocyanurate resins having at least one pendant acrylate group, and isocyanate resins having at least one pendant acrylate group.

5. An abrasive article in accordance with claim 1 further characterized by the clay particles having an average particle size ranging from about 0.01 micrometer to about 50 micrometers.

6. An abrasive article in accordance with claim 1 further characterized by the composite being on a dry weight basis from about 20 to about 95 percent abrasive particles, from about 3 to about 78 percent addition polymerized resin, and from about 2 to about 50 percent clay particles.

7. A method of making an abrasive article characterized by the steps of:

1) coating a slurry onto a production tool having a three dimensional pattern, the slurry comprising an addition polymerizable resin, abrasive particles, and clay particles;
2) contacting a substrate having at least one major surface with the slurry so that the slurry wets said at least one major surface of the substrate, thus forming a first intermediate article;
3) exposing the slurry to conditions sufficient to at least partially cure the addition polymerizable resin to form a second intermediate article; and 4) removing the second intermediate article from the production tool, yielding an abrasive article.