CA2116686A1

CA2116686A1 - A coated abrasive belt with an endless, seamless backing and method of preparation

Info

Publication number: CA2116686A1
Application number: CA002116686A
Authority: CA
Inventors: Harold Wayne Benedict; Diana Denise Zimny; Donna Wendeln Bange
Original assignee: Individual
Current assignee: 3M Co
Priority date: 1991-12-20
Filing date: 1992-10-30
Publication date: 1993-07-08
Also published as: ATE176883T1; RU94017857A; US5573619A; WO1993012911A1; CN1072092C; EP0619769A1; NO942334D0; CN1073388A; TW216447B; RU2116186C1; NO942334L; BR9206806A; US5609706A; AU3058192A; KR0161543B1; EP0619769B1; DE69228487T2; AU665384B2; JPH07502458A; DE69228487D1

Abstract

A coated abrasive backing consisting of an endless, seamless, loop is provided. The backing loop includes 40-99 % by weight of an organic polymeric binder, based upon the weight of the backing; and an effective amount of a fibrous reinforcing material engulfed within the organic polymeric binder material. The endless, seamless backing loop includes a length with paral-lel side edges, and at least one layer of fibrous reinforcing material engulfed within the organic polymeric binder material such that there are regions of organic binder material free of fibrous reinforcing material on opposite surfaces of the layer of fibrous reinforcing material. The fibrous reinforcing material can be in the form of individual fibrous strands, a fibrous mat structure, or a combination of these. A method for preparing the endless, seamless backing loop for a coated abrasive belt is also provided.
The method includes the steps of preparing a loop of liquid binder material having fibrous reinforcing material therein around the periphery of a drum; and solidifying the binder material such that an endless, seamless, backing loop having fibrous reinfor-cing material engulfed within the organic polymeric binder material is formed.

Description

WO 93/12911 ~ 1 1 U ~ ~3 6 PCr/US92~09331 A COATED ABRASIVE BELT WITH AN ENDLESS, SEAMLESS BACK~G AND METHOD OF PREPARATION
s The present invention pertains to coated abrasive articles, and particularlyto coated abrasive belts with endless, seamless backings containing an organic polymeric binder and a fibrous reinforcing material. Additionally, this invention pertains to methods of making endless, seamless backings for use in coated 10 abrasive belts.
Coated abrasive articles generally contain an abrasive matenal, typically in the form of abrasive grains, bonded to a backing by means of one or more adhesive layers. Such articles usually take the form of sheets, discs, bèlts, bands, and the like, which can be adapted to be mounted on pulleys, wheels, or drums.
15 Abrasive articles can be used for sanding, grinding, or polishing various surfaces of, for example, steel and other metals, wood, wood-like laminates, plastic, fiberglass, leather, or ceramics.
The backings used in coated abrasive articles are typically made of paper, - polymeric matenals, cloth, nonwoven materials, vulcanized fiber, or combinations 20 of these materials. Many of these materials provide unacceptable backings for `~
certain applications because they are not of sufficient strength, flexibility, or impact resistance. Some of these materials age unaeceptably rapidly. Also, some are sensitive to liquids that are used as coolants and cutting fluids. As a result, early failure and poor functioning can occur in certain applications.
In a typical manufacturing process, a coated abrasive article is made in a continuous web form and then converted into a desired construction, such as a sheet, disc, belt, or the like. One of the most useful constructions of a coatedabrasive article is an endless coated abrasive belt, i.e., a continuous loop of coated abrasive material. In order to form such an endless belt, the web form is typically 30 cut into an elongate strip of a desired width and length. The ends of the elongate strip are then joined together to create a "joint" or a "splice." "
Two types of splices are common in endless abrasive bslts. These are the "lap" splice and the "butt" splice. For the lap splice, the ends of the elongate strip ~.

WO 93/12911 Pcr/lJs92/o933l .'li~i`8~ ~

- 2 -are bevelled such that the top surface with the abrasive coating and the bottom surface of the backing fit together without a significant change in the overall thickness of the belt. This is typically done by removing abrasive grains from the abrasive surface of the strip at one of the ends, and by removing part of the 5 material from the backing of the elongate strip at the other end. The bevelled ends are then overlapped and joined adhesively. For the butt splice, the bottom surface of the backing at each end of the elongate strip is coated with an adhesive and overlaid with a str~ng, thin, tear-resistant, splicing media. Although endless coated abrasive belts containing a splice in the backing are widely used in industry 10 today, these products suffer from some disadvantages which can be attributed to the splice.
- For example, the spllce is generally thicker than the rest of the coated abrasive belt, even though the methods of splicing generally used involve attempts to mmimize this variation in the thickness along the length of the belt. This can 15 ~ead ~to ~a region(s) on the workpiece with a "coarser" surface finish than the remainder of the workpiece, which is highly undesirable especially in high precision~ grinding applications. For examplè, wood with areas having a coarser sur~oe finish will stain darker than the remainder of the wood.
Also, the spllce can be the weakest~area or link in thé coated abrasive belt.
20- In some instances, the splice will break prematurely before full u~ilization of the c~ated abrasive belt. Belts have therefore often been made with laminated ~inersor backings to give added strength and support. Such belts can be relatively expensive and under certain conditions can be subject to separation of the laminated layers.
In addition, abrading machines that utilize a coated abrasive belt can have difficulty properly tracking and aligning the belt because of the splice. Further, ,,. j I : i , ~
the splice creates a discontinuity in the coated abrasive belt. Also, the splice area ~- can be undesirably more stiff than the remainder of the belt. Finally, the splice in the belt backing adds considerable expense in the manufacturing process of 30 coated abrasive belts.

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Wo93/12911 ~ 8 ~ Pcr/Us92/09331 ~ he present invention is directed to coated abrasive articles, particularly to coated abrasive belts made from endless, seamless backing loops. By the phrase "endless, seamless" it is meant that the backings, i.e., backing loops, used in the belts are continuous in structure throughout their length. That is, they are free S from any distinct splices or joints. This does not mean, however, that there are no intemal splices in, for example, a fibrous reinforcing layer, or that there are no splices in an abrasive layer. Rather, it means that there are no splices or joints in the backing that result from joining the ends of an elongate strip of backingmaterial.
10Typically, the thickness of the endless, seamless backing loops of the present invention does not vary by more than 15% along the entire length of the loop and preferably varies less than 10%, more~preferably less than 5% and most : :;
preferably less than 2%.
A coaled abradve belt of the present invention includes a backing in the 15 form o f an èndless, seamless loop, which contains an organic polymeric binder - ma~erial~and a~fibrous reinforcing material. Typic;~ly, the binder weight In the backing is within a range of 4~99 wt-%, preferably within a range of 50-95 wt-%,more prefe ably within a range of 65-92 wt- %, and most preferably within a range o f 7~8S~ wt-~o, based on the~ total weight of the backing. The polymeric binder20 maleri~ can be a thermosetting, thermoplastic, or elastomeric material or a combination thereof. Preferably it is a thermosetting or thermoplastic material.Moro preferaUy it is a thermosetting material. ln some instances, the use of a combination of a thermosetting material and an dastomeric material is preferable.
The remainder of a typical, preferred, backing is primarily fibrous 25 reinforcing material. Although there may be additional components added to the binder composition, a coated abrasive backing of the present invention primaIily .
contains an organic polymeric binder and an effective amount of a fibrous reinforcing material. The phrase "effective amount" of fibrous reinforcing material refers to an amount suMcient to give the desired physical characteristics 30 of the backing such as reduction in stretching or splitting durisng use.

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The organic polymeric binder material and fibrous reinforcing materîal together comprise a flexible composition, i.e., flexible backing, in the form of an endless, seamless loop with generally parallel side edges. The flexible, endless, seamless backing loop includes at least one layer of fibrous reinforcing matedalS along the entire length of the belt. This layer of fibrous reinforcing matelial is preferably substantially completely surrounded by (i.e., engulfed within) the organic polymeric binder matedal. That is, the layer of fibrous reinforcing rnatedal is embedded or engulfed within *e internal structure of the loop, i.e.,within the body of the loop, such that there are regions of organic binder material 10 free of fibrous rdnforcing material on opposite surfaces of the layer of fibrous reinforcing material. In this way, the surfaces, e.g., the outer and inner surfaces, of the loop have a generally smooth, uniform surface topology.
The fibrous reinforcing material can be in the form of individual fibrous strands or a fibrous mat structure. The endless, seamless loops, i.e., backing - ~ 15 loops, of the present invention preferably consist of various layers of individual fibrous ~reinforcmg ~strands and/or fibrous mat structures incorporated within, i.e., engulfed within, an internal structure or body ;of the backing. Preferred belts rdain, for example, a thermosetting binder, 8 layer of noninterlacing parallel and cophnar individual fibrous reinforcing strands, and a layer of a fibrous mat ~20 ~structure wherein the fibrous material within one layer does not interlock with the fibrous material within the other layer.
Certain preferred belts of the present invention also contain a preformed abrasive coated laminate. This preformed laminate typically comprise a sheet material, i.e., material in the form of a sheet, coated with abrasive grains. The 2~5 pleforrned abrasive coated laminate can be laminated, i.e., attachedl to the outer sur~a~ of the bachng of the present invention using a variety of means, such as an adhesive or mechanical fastening means. This embodiment of the coated abrasive article of the present invention is advantageous at least because of the potential for removing the laminate once the abrasive material is exhausted and ;~ ~ 30; ~replacing~it with another such laminate. ~In this way the backing of the present invention can be reused. The term "preformed" in this context is meant to indicate , WO 93/1291 1 ~ i PCr/US92/09331 .

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t4at the abrasive coated laminate is prepared as a self-supporting sheet coated with abrasive material and subsequently applied to the endless, seamless backing loops of the present invention. Such embodiments typically have a seam in this preformed coated abrasive laminate layer. The backing loop, however, does not S contain a searn or joint. Furthermore, the backing loop is not made of preformed and precured layers adhesively laminated together.
The coated abrasive backings of the present invention are prepared by:
preparing a loop of liquid organic binder material having fibrous reinforcing material therein, in extension around a periphery of a support structure, such as 10 a drum; and solidifying the liquid organic binder material such that a flexible, solidified, endless, seamless backing loop having fibrous reinforcing material therein is formed. The flexible, solidified, endless, seamless backing loop formed has an outer and an inner surface. The step of prepanng a loop of liquid organicbinder material having fibrous reinforcing material therein preferably includes the lS steps of: applying a fibrous reinforcing mat structure around the periphery of a sup~ort structure, such as a drum; and winding one individual reinforcing strandaround the periphery of the support structure, e.g., drum, in the form of a helix in longitudinal extension around the backing loop? i.e., along the length of thebacldng, in a layer that spans the width of the backing.
An alternative, and preferred method of prepanng the endless, seamless loops of the present invention includes coating, i.e., impregnating, the fibrous, reinforcing mat structure with the liquid organic binder material prior to beinga~plied around the periphery of the support structure. One method of împregnating the fibrous reinforcing material is to coat the fibers through an 25 orifice with the binder material. If the organic binder material is a solid material, such as a thermoplastic material, the step of preparing a loop of liquid organicbinder material having fibrous reinforcing material therein includes: applying afirst layer of a solid organic binder material around the periphery of a supportstructure, preferably a drum; applying a layer of fibrous reinforcing material 30 around the first layer of solid organic polymeric binder material on the support structure; applying a second layer of a solid organic polymeric binder material wo 93/12911 i~ j 8 6 Pcr/usg2/o9331 -around the firsl layer of solid organic polymeric binder material and the layer of fibrous reinforcing material on the support structure to fiorm a structure of a solid organic polymeric binder material having a layer of fibrous reinforcing materialtherein; and heating the solid organic polymeric binder material until it flows and 5 gene~ally forms a liquid organic polymeric binder material having fibrous reinforcing material therein. Herein, the term Nliquid" refers to a material that is flowable or flowing, whereas the term Nsolid" or "solidified" refers to a material that does not readily flow under ambient temperatures and pressures, and is meant to include a thixotropic gel.
The flexible backing compositions of the invention can be coated with adhesive and abrasive layers using any conventional manner. Typically, and prcferably, this involves: applying a first adhesive layer to the outer surface of a solidified, endless, seamless, loop having fibrous reinforcing material therein;embedding an abrasive material into the first adhesive layer; and, at least partially 15 solidifying the first adhesive layer. The abrasive material, preferably in the form ;of grains, can be applied electrostabcally or by drop coating. In preferred applicaiions, a second adhesiw layer is applied over the abrasive material and first adhesive layer; and both the first and second adheslve layers are fully solidified.
Alternatively, the first adhesive layer and the abrasive layer can be applied 20 in one step by applying an abrasive slurry to the outer surface of the backing. The abrasivè slurry includes an adhesive resin and an abrasive material, prefe~bly aplurality of abrasive grains. The adhesive resin is then preferably at least partially solidified. A second adhesive layer can then be applied. In certain preferred applications of the present invention, a third adhesive layer can ~e applied if 25 desired.
Similar methods can also be used in preparing a coated abrasive backing using a support structure, such as a conveyor system. Such a system would typically use, for example, a stainless steel sleeve, in the form of a conveyor belt.
ln this embodiment, the step of preparing a loop of liquid organic binder material 30 includes prepanng the loop around the conveyor belt.

Wo 93/12911 Pcrfuss2/o933l 8 ~

Fig. 1 is a perspective view of a coated abrasive belt formed from an endless, seamless, backing loop according to the invention; Fig. 1 being schematic in nature to reflect construction according to the present invention.
Flg. 2 is an enlarged fragmentary cross-sectional view of a coated abrasive 5 belt according to the present invention taken generally along line 2-2, Fig. 1.
Fig. 3 is a perspective view of an endless, seamless, backing loop according to the invention; Fig. 3 being schematic in nature to reflect construction according to the present invention. ~`
~ Ig. 4 is an enlarged fragmentary cross-sectional view of an endless, 10 seamless bacl~ng loop according to the present invention taken generally along line 4-4, Fig. 3. The figure is schematic in nature to reflect a construction of the internal fibrous network in an endless, seamless, backing loop of this invention.
Fig. 5 is an enlarged fragmentary cross-sectional view of an endless, seamless backing loop according to the present invention taken generally 15 analogously along line 4-4, Fig 3. The figure is schematic in nature to reflect an alternative construction of the internal fibrous network in an endless, seamless, bacldng loop of this invention.
Flg. 6 is an enlarged fragmentary cross-sectional view of an endless, seamless bacldng loop according to the present invention taken generally 20 analogously along line 4-4, Fig. 3. The figure is schematic in nature to reflect an alternative construction of the inten~al fibrous network in an endless, sean~ess, backing loop of this invention.
Fig. 7 is a side view of an apparatus for applying the binder to a drum.
Fig. 8 is a schematic of a preferred process of the present invention for 25 mal~ng an endless, seamless backing loop containing bo~h a fibrous reinforcing rnat structure and a layer of a continuous fibrous reinforcing strand engulfed within a the~mosetting resin.
Fig~ 9 is a schematic of an alternative process for making an endless, seamless backing loop using a conveyor system in place of a drum in a process for 30 making an endless, seamless backing loop.

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wo 93tl2s1~ ; Pcr/us92/o933 Fig. lO is a perspective view of another embodiment of an endless, seamless backing loop wherein reinforcing yarns are located only near the centerof the loop.
Flg. Il is a perspective view of still another embodiment of an endless, S seamless bacWng loop wherein reinforcing yarns are located only at the edges of the loop.
Flg. 12 is a perspective view of yet another embodiment of an endless, seamless bacWng loop wherein one region comprises a binder, a reinforcing strandand a reinforcing mat, and the second region comprises only a binder and a 10 reinforcing mat.
Referring to Fig. 1, a coated abrasive belt 1, according to the present invention, is illustrated which incorporates the construction illustrated in Fig. 2.
WorWng surface 3, i.e., the outer surface, of the belt I includes abrasive material in the form of abrasive glains 4 adhered to an endless, seamless backing loop 5 lS of the coated abrasive belt l. The irmer surface 6, i.e.~ the surface opposite that coated with the abrasive rnatenal is generally smooth. By "smooth" it is meant that there is generally no protruding fibrous reinforcing material. Refemng to Pig. 2, in general, a coated abrasive belt 1 (Fig. l) includes: a backing 5; and a first adhesive layer 12, commonly ref~rred to as the make coat, applied to a 20 surface 13 of the backing 5. Herein, "coated abrasive" refers to an article with the abrasive matenal coated on the outer surface of the article. It is typicaHy not meant to include articles wherein the abrasive grain is included within the backing.
The pu~se of the ~lrst adhesive layer l2 is to secure an abrasive material, preferably in the form of a plurality of abrasive grains 4, to the surface l3 of the 25 backing 5. Referring to Fig. 2, a second adhesive layer 15, commonly referredto as a siæ coat, is coated over the abrasive grains 4 and first adhesive layer 12.
The purpose of the second adhesive layer lS is to reinforce the securement of abrasive grains 4. A third adhesive layer 16, commonly referr~ to as a supersizecoat, is applied over the second adhesive layer l5. The supersize coat may be a 30 release coating that prevents the coated abrasive from loading. "Loading" is the term used to describe the filling of spaces between abrasive particles with swarf Wo93/12911 ~ ~ 8 6 Pcr/usg2/o933l ~
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g (the material abraded from the workpiece) and the subsequent build-up of that material. Examples of loading resistant materials include metal salts of fatty acids, urea-formaldehyde, waxes, mineral oils, cross-linked silanes, cross-linked silicones, fluorochemicals and combinations thereof. A preferred material is zinc S stearate. The third adhesive layer 16 is optional and is typically utilized in coated abrasive articles that abrade generally hard surfaces, such as stainless steel or cxotic metal workpieces.
Referring again to Fig. 1, the coated abrasive belt 1 can generally be of any size desired for a particular applicadon. The length "L", width "W", and 10 thichless "T", can be of a variety of dimensions desired depending on the end use.
Although the thickness "T" is shown in Fig. I with respect to a construction of a coated abrasive belt 1, the thickness "Tl" referred to herein, refers to the thickness of the endless, seamless backing loop S, Fig. 2.
The length "L" of the coated abrasive belt 1 can be any desired length.
15 Typically, it~ is 40-lS00 centimeters (cm). The thickness "Tl" of the endless, seamless ~backing loop S is typically between 0.07 millimeter (mm~ and 1.5 mm for optimum flexibility, strength, and material conservation. Preferably, he thi~lmess of the endless, seamless backing 5 is between 0.1 and 1.0 millimeter, -~ and more preferably between 0.2 and 0.8 millimeter for coated abrasive 20 applications. The thickness ~T1 " of the endless, seamless backing loop 5 of coated abrasive belt I does not generally va~y by more than 15% around the entire length "L" of the belt 1, Fig. 1. Preferably, the thickness ''Tl'' throughout the entire endless, seamless backing loop 5 does not vary by more thar 10%, more preferably by no more than 5% and most preferably by no more than 2%.
25 Although this variance refers to a variance along the thickness ''Tl'' of the backing 5t this variance also generally applies to a backing coated with adhesives and abrasive material, i.e., the thickness ~T" of the belt 1.
The preferred coated abrasive articles of the present invention generally include a backing wlth the foliowing properties. The backing is sufficiently heat 30 resist~nt under grinding conditions for which the abrasive article is intended to be used~ such that the backing does not significantly disintegrate, i.e., split, break, , ~

wo 93/1291 1 L ~ 8 ~ pcr/us92/o9331 " " ' `?
10 - I :
delaminate, tear, or a combination of these, as a result of the heat generated during a grinding, sanding, or polishing operation. The backing is also sufficiently tough such that it will not significantly crack or shatter from the forces encounteredunder grinding conditions for which the abrasive article is intended to be used.S That is, it is sufficiently stiff to withstand typical grinding conditions encountered by coated abrasive belts, but not undesirably brittle.
Preferred backings of the present invention are sufficiently flexible to withstand grinding conditions. By "sufficient flexibility" and variants thereof in this context, it is meant that the backings will bend and return to their original 10 shape without significant permanent deformation. For example, a continuous "flexible" backing loop is one that is sufficiently flexible to be used on a two (or - more) roller mount or a two (or more) pulley mount in a grinder. Furthermore, for preferred grinding applications, the backing is capable of flexing and adapting to the contour of the workpiece bdng abraded, yet is sufficiently strong to transmit 15 an effective grinding force when pressed against the workpiece.
Prefened back~ings of the present invention possess a generally uniform tensile strength in the longitudinal, i.e., machine direction. This is typicallybecause the reinforcing material extends along the entire length of the backing and because there is no seam. More preferably, the tensile strength for any portion of 20 a backing loop tested does not vary by more than 20% from that of any other portion of the backing loop. Tensile strength is generally a measure af the maximum stress a material subjected to a stretching load can withstand without tearing.
Preferred bacl~ngs of the present inven~ion also exhibit appropriate shape 25 control and are sufficiently insensitive to environmental conditions, such ashumidity and temperature. By this it is meant that preferred coated abrasive backings of the present invention possess the above-listed properties under a wide range of environmental conditions. Preferably, the backings possess the above-listed properties within a temperature range of 10-30C, and a humidity range of30 30-50% relative humidity (RH). More preferably, the backings possess the above-listed properties under a wide range of temperatures, i.e., from below 0C to ~,:

w~ 93Jl2911 ~ 1 ~ ~ ~ 8 6 Pcr/usg2/o933l 1 1 , above 100C, and a wide range of humidity values, from below 10% RH to above 90% RH. -Under extreme conditions of humidity, i.e., conditions of high humidity(greater than 90%) and low humidity (less than 1096), the backing of the present 5 invention will not be significantly effected by eitha expansion or shrinkage due, respectively, to water absorption or loss. As a result, a coated abrasive belt made with a backing of the present invention will not significantly cup or curl in either a concave or a conve% fashion.
The preferred backing material used in coated abrasive belts of the present 10 invantion is generally chosen such that there will be compatibility with, and good adhesion to, the adhesive layers, particularly to the make coat. Good adhesion is deterinined by the amount of "shelling" of the abrasive material. Shelling is a term used in the abrasive industry to describe the undesired, premature, release of a~ sîgnifi~t amount of the abrasive rnaterial from the backing. Although the 15 clioice~of backing matcrial is Important, the amount of shelling typically depends to~ a ~ extent on the choice of adhesive and the compatibility of the backing and adhesivo layers.
Examples of thermosetting resins from which the backing can be prepared ~ include phenolic resins, amina resms, polyester resins, aminoplast resins, urethane 20 ~ restns~melamine-formaldehyde resins, epoxy resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated urethane resins, acry~ated epoxy resins or mixtures thereof. The prefelTed thermosetting resins are epoxy resins, urethane resins, polyester resins, or flexible phenolic resins. The mostprefelTed resins are epoxy resins and urethane resins, at least because they exhibit 25 an acc~ble cure rate, flexibility, good ther nal stability, strength, and water resistance. Further nore, in the uncured state, typical epoxy resins have low viscosity, ewn at high percent solids. Also, there are many suitable urethanes available at high percent solids.
~; ~Phenolic resins are usually cat~egorized as ~esole or novolac phenolic resins.
30;~ Exatnples~;of~useful~ commerci~ly~ availa~ble phenolic resins are "Varcum`' from Bll, Spocialty~Resins Corporation, Blue Island, IL; "Arofene" from Ashland ,, ~ , . , ~
, . :

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WO 93/1291 1 ~ ~ 8 PCr~US92/09331 Chemical Company, Columbus, OH; NBalcelite" from Union Carbide, Danbury, CT; and "Resinox" from Monsanto Chemical Company, St. Louis, MO.
Resole phenolic resins are characterized by being alkaline catalyzed and having a molar ratio of formaldehyde to phenol of greater than or equal to 1~
S Typically, the ratio of formaldehyde to phenol is within a range of 1:1 to 3:1.
Examples of alkaline catalysts useable to prepare resole phenolic resins includesodium hydroxide, potassium hydroxide, organic amines, or sodium carbonate.
Novolac phenolic resins are characterized by being acid catalyzed and having a molar ratio of formaldehyde to phenol of less than 1:1. Typically, the 10 ratio of formaldehyde to phenol is within a range of 0.4:1 to 0.9:1. Examples of the acid catalysts used to prepare novolac phenolic resins include sulfuric, hydrochloric, phosphoric, oxalic, or p-toluenesulfonic acids. Although novolac phenolic resins are typically considered to be thermoplastic resins rather than thermosetting resins, they can reaa with other chemicals (e.g., 15 hexamethylenetetraamine) to forrn a cured thermosetting resin.
Epoxy resins useful in the polymerizable mixture used to prepare the hardened backings of this invention include monome~ic or polymeric epoxides.
Useful epoxy materials, i.e., epoxides, can vary greatly in the nature of their backbones and substituent groups. Representative examples of acceptable 20 substituent groups include halogens, ester groups, ether groups, sulfonate groups, siloxane groups, nitro groups, or phosphate groups. The weight average moleeularweight of the epoxy-eontaining polymeric materials can vary from 60 to 400Q, andare preferably within a range of 100 to 600. Mixtures of various epoxy-containing materials can be used in the compositions of this invention. Examples of 25 commercially available epoxy resins include "Epon" from Shell Chemical, Houston, TX; and "DER" from Dow Chemical Company, Midland, Ml.
Examples of commercially available urea-formaldehyde resins include "Uformite" from Rcichhold Chemical, Inc., Durham, NC; "~urite" from Borden Chemical Co., Columbus, OH; and "Resimene" from Monsanto, St. Louis, MO.
30 Examples of commercially available melamine-formaldehyde resins include "Uformite~ from Reichhold Chemical, Inc., Durham, NC; and "Resimene" from W0 93/12gl l ~ i PCl`/US92/09331 Monsanto, St. Louis, MO. "Resimene" is used to refer to both urea-formaldehyde and melamine-formaldehyde resins.
Examples of aminoplast resins useful in applications according to the present invention are those having at least 1.1 pendant a,~-unsaturated carbonyl5 groups per molecule, which are disclosed in U.S. Patent 4,903,440.
Us~able acrylated isocyanurate resins are those prepared from a mixture of:
at least one monomer selected from the group consisting of isocyanurate derivatives having at least one terminal or pendant acrylate group and isocyanate derivatives having at least one terminal or pendant acrylate group; and at least one 10 aliphatic or cycloaliphatic monomer having at least one terminal or pendant acrylate group. These acrylated isocyanurate resins are described in U.S. Patent4,652,274.
Acrylated urethanes are diacrylate esters of hydroxy terminated -NCO-ext0ded polyesters or polyeths. Examples of commercially available acrylated 15 urethanes-useful in applications of the present invention include those having the trade names "Uvithane 782,H available from Morton ThiokoI Chemical, Chicago, IL,~ ~Ebeciyl 6600, ~ "Ebecryl 8400," and "Ebecryl 88-5, " available from Radcure Specialties, Atlanta, GA.
The acrylated epoxies are diacrylate esters, such as the diacrylate esters of 20 bisphenol A epoxy resin. Examples of commercially available acrylated epoxiesinclude those having the trade names "Ebecryl 350Q," "Ebecryl 3600," and "Ebecryl 8805," available from Radcure Specialties, Atlanta, GA.
Suitable thermosetting polyester resins are available as "E-737" or "E-650"
from Owens-Corning Fiberglass Corp., Toledo, OH. Suitable polyurethanes are 25 available as ~'Vibrathane B-813 prepolymer" or "Adiprene BL-16 prepolymer"
used with "Caytur-31" curative. All are available from Uniroyal Chemical, Middlebury, CT.
As indicated previously, in some applications of the present invention, a thermoplastic binder material can be used, as opposed to the preferred - 30 thermosetting resins discussed above. A thermoplastic binder material is a polymeric material that softens when exposed to elevated temperatures and: , WO 93/12911 2 i 1 b ~ 8 6 Pcr/us92/

generally returns ~to its original physical state when cooled to ambient temperatures. During the manufacturing process, the thermoplastic binder is heated above its softening temperature, and often above its melting temperature,to form the desired shape of the coated abrasive backing. After the backing is 5 formed, the thermoplastic binder is cooled and solidified. Thus, with a thermoplastic material, injection molding can be used to advantage.
Preferred thermoplastic materials of the invention are those having a high melting temperature and/or good heat resistant properties. That is, preferred thermoplastic materials have a melting point of at least 100C, preferably at least 10 150C. Additionally, the melting point of the preferred thermoplastic materials is sufficiently lower, i.e., at least 25C lower, than the melting temperature of the ~
reinforcing material. -Examples of thermoplastic materials suitable for preparations of backings in articles according to the present invention include polycarbonates, 15 polyetherimides, polyesters, polysulfones, polystyrenes, acrylonitrile-butadiene-styrene block copolyms, poIypropylenes, acetal polymers, polyamides, polyvinyl chlorides, polyethylenes, polyurethanes, or combinations thereof. Of this list, polyamides, polyurethanes, and polyvinyl chlorides are preferred, with polyurethanes and polyvinyl chlorides being most preferred.
If the thermoplastic material from which fhe backing is formed is a polycarbonate, polyetherimide, polyester, polysulfone, or polystyrene materqal, a primer can be used to enhance the adhesion between the backing and the make coat. The term "primer" is meant to include both mechanical and chemical type primers or priming processes. This is not meant to include a layer of cloth or 25 fabric attached to the surface of the backing. Examples of mechanical primersinclude, but are not limit~d to, corona treatment and scuffing, both of which increase the surface area of the surface. An example of a preferred chemical primer is a colloidal dispersion of, for example, polyurethane, acetone, a colloidal oxide of silicon, isopropanol, and water, as taught by U.S. Patent No. 4,906,523.
A third type of binder useful in the backings of the present invention is an elastomer~ic material. An elastomenc material, i.e., elastomer, is defined as a .

Wo 93/12911 ~ 1 i ~ ~ 8 ~ pcr/us92/o933 ; material that can be. stretched to at least twice its original length and then retract very rapidly to approximately its original length, when released. Examples of elastomeric materials useful in applications of the present invention include styrene-butadiene copolymers, polychloroprene (neoprene), nitrile rubber, butyl S rubber, polysulfide rubber, cis-1,4-polyisoprene, ethylene-propylene terpolymers, silicone rubber, or polyurethane rubber. ln some instances, the elastomeric materials can be cross-linked with sulfur, peroxides, or similar curing agents to form cured thermosefflng resins.
Besides the organic polymeric binder material, the backing of the present 10 invention includes an effcctive amount of a fibrous reinforcing material. Herem, an "effective amount" of a fibrous reinforcing material is a sufficient amount to impa t at least Improvement in desirable charactcristics to the backing as discussed above, but not so much as to give rise to any significant number of voids and detriment~lly effect~the structural integrity of the backing. Typically, the amount 15 of ~e;fibrr~us ranforci`ng material m the backing is wlthin a range of 1-60 wt- %~
preferably 5 50 wti%~,~more prcferably 8-35 wt-%, and most preferably 15-30 wt-% ,~ based ~on~ tbe total weight of the backing~.
- .
The fibrous reinforcing ma:terial can be in the form of fibrous strands, a fiber ~mat or web, or a swltchbonded or weft~insertion mat. Fibrous strands are 20~- commercially available as threads, cords, yarns, rovings, and filaments. Threads and cords are typically assemblages of yarns. A thread has a very high degree oftwist with a low friction surface. A cord car be assembled by braiding or twisting yarns and is genera11y larger than a thread. A yarn is a plurality of fibers or filaments either twisted together or entangled. A roving is a plurality of fibers or 25 filaments pulled together either without a twist or with minimal twist. A filament is a continuous fiber. ~ Both ~rovings and yarns are composed of individual filaments. A fiber mat or web consists of a matrix of fibers, i.e., fine threadlike pieces with an aspect ratio of at least 100:1. The aspect ratio of a fiber is the ratio of the longer dimension of the fiber to the shorter dimension.
The~fiblous reinforcing~ material~ can be~ comp~sed of any material that increases~:the stre:ngth of~;the~bachng. Examples of useful reinforcing fibrous ,,:

, , .

WO93/111 ~ PCI/US92/09331 - 16- ' ~
material in applications of the present invention include metallic or nonmetallic `
fibrous material. The preferred fibrous ma~erial is nonmetallic. The nonmetallicfibrous materials may be materials made of glass, carbon, minerals, synthetic ornatural heat resistant organic materials, or ceramic materials. Preferred fibrous 5 reinforcing materials for applications of the present invention are organic materials, glass, and ceramic fibrous material.
By "heat resistant" organic fibrous material, it is meant that useable organic materials should be sufficient1y resistant to melting, or other vise softening or breaking down, under the conditions of manufacture and use of the coated abrasive 10 backings of the present invention. Useful natural organic fibrous materials include wool, silk, cotton, or cdlulose. Examples of useful synthetic organic fibrous materials are mad& from polyvinyl alcohol, nylon? polyester, rayon, polyamide, acrylic, polyolefin, aramid, or phenol. The preferred organic fibrous material for applications of the present invention is aramid fibrous material. Such a material , 15 is commercially available from the Dupont Co., Wilmington, DE under the trade names of nKevlarn and "Nomex."
Generally, any ceramic fibrous reinforcing material is useful in applications of the present invention. An example of a ceramic fibrous reinforcing material - ~ ~ suitable for the present invention is "Nextel" which is commercially available from 20 3M Co., St. Paul, MN. Examples of useful, commercially available, glass fibrous reinforcing material in yarn or roving form are those available fronrPPGIndustries, lnc. Pittsburgh, PA, under the product name E-glass bobbin yarn;
Owens Corning, Toledo, OH, under the product name "Fiberglass" continuous filament yarn; and Manville Colporation, Toledo, OH, under the product name 25 "Star Rov 502" fiberglass roving. The size of glass fiber yarns and rovings are typically expressed in units of yards/lb. Useful grades of such yarns and rovings are in the range of 75 to 15,000 yardstlb, which are also preferred.
If glass fibrous reinforcing material is used, it is preferred that the glass fibrous material be accompanied~ by an interfacial binding agent, i.e., a coupling 30 agent, wch as a silane coupling agent, to improve adhesion to the organic binder ma~rial, particularly if a thermoplastic binder material is used. Examples of .
:

Wo 93/129~ 8 6 Pcr/~ss2/o9331 -- 17 -- , silane coupling agents include Dow-Corning "Z-6020" or Dow Corning "Z-6040 both available from Dow-Corning Corp., Midland, MI.
Advantages can be obtained through use of fibrous reinforcing materials of a length as short as 100 micrometers, or as long as needed for a fibrous 5 reinforcing layer formed from one continuous strand. It is preferred that the fibrous reinforcing material used be in the form of essentially one continuous strand per layer of reinforcing material. That is, it is preferred that the fibrous reinforcing material is of a length sufficient to extend around the length, i.e., circumference, of the coated abrasive loop a plurality of times and provide at least 10 one distinct layer of fibrous reinforcing material.
The reinforcing fiber denier, i.e., degree of fineness, for preferred fibrous reinforcing~ma~erial~rangès from 5 to 5000 denier, typically between 50 and 2000denier. More prefdly, the fiber denier will be between 200 and 1200, and most preferaoly between; 500 and 1000. It is understood that the`denier i~ strongly 15 influenced~by~the particular type of fibrous réinforcing material employed.
A ~plimaly purpose of a mat or web structure is to increase the tear resistance~of the coated abrasive backing. The mat~or web can be either in a woven or a nonwoven forrn. Preferably, the mat consists of nonwoven fibrous ma~ial at~ least because of its openness, nondirectional strength characteristics, 20'~and10wcost.
A nonwoven mat is a matrix of a random'distribution of fibers. This matrix is usually formed by bonding fibers together either autogeneously or by an adhesive. That is, a nonwoven mat is generally described as a sheet or web structure made by bonding or entangling fibers or filaments by mechanical, 25 thermaL orchemical means.
Examples of nonwoven forms suitable for this invention include st,aple bonded, spun bonded, melt blown, needle punched, or thermo-bonded forms. A
nonwoven web is typically porous, having a porosity of 15% or more. Depending upon~the~particular nonwoven employed, the fiber length can range from 100 30 ~ micrometers to infinity, i.e., continuous fibrous stran~ds. Nonwoven mats or webs re further desc ibed in ~"The Nonwovens Handbook" edited by Bernard M.

Wo 93~1291 ~ PCr/Uss2/0933l . . .

Lichstein, published by the Association of the Nonwoven Fabrics Industry, New York, l988.
The thickness of the fibrous mat structure when applied in typical applications of the present invention generally ranges from 25 to 800 micrometers, 5 preferably from 100 to 375 micrometers. The weight of a preferred fibrous mat structure generally ranges from 7 to 150 grams/square meter (g/m2), preferably from l7 to 70 g/m2. In certain preferred applications of the present invention, the backing contains only one layer of the fibrous mat structure. In other preferredembodiments it can contain multiple distinct layers of the fibrous mat structure10 distributedthroughoutthebinder. Preferably,thereareltolOlayers,andmore preferably 2 to S layers, of the fibrous mat structure in backings of the present invention. Preferably l-50 wt %, and more preferably 5-20 wt %, of the preferred backings of the present invention is the fibrous reinforcing mat.
The type of fibrous rdnforcement chosen typically depends on the organic 15 polymeric binder material chosen and the use of the finished product. For example, if a thermoplastic binder material is desired, reinforcement strands are important for imparting strength in the longitudinal direction. The binder material itself generally has good cross-belt strength and flexibility, i.e., in the direction of the width of the belt. If a thermosettîng binder material is desired, a fibrous mat 20 structure is important for imparting streng~h and tear resistance.
The endless, seamless backing loops of the present invention preferabl~and advantageously include a combination of fibrous rem~orcing strands and a fibrousmat structure. The fibrous strands can be individual strands embedded within thefibrous mat stmcture for advantage, at least with respect to manufacturing ease.25 The fibrous strands can also form distinct layer(s) separate from, i.e., noninterlocking or intertwining with, the fibrous mat structure.
The fibrous mat structure is advantageous at least because it ~enerally increases the tear resistance of the endless, seamless loops of the present invention.
For endless, seamless loops that include both fibrous reinforcing strands and a 30 fibrous mat stn~cture, the fibrous mat structure is preferably l-50 wt %, more prefe~ly 5-20 wt %, of the backing composition, and the fibrous reinforcing ,~

~, W093/12gll 2 1 ~ 6 ~ 8 6 Pcr/uss2/o933l - 19 - ~
strands are preferably 5-50 weight percent, more preferably 7-25 wt %, of the backing composition.
As stated above, the fibrous reinforcing material can also be in the form of a mat structure containing adhesive or melt-bondable fibers used to integrateS parallel strands of individual fibers. In this way, "individual" parallel strands are embedded, i.e., incorporated, within a fibrous reinforcing mat. These parallel strands can be in direct contact with each other along their length, or they can be ssparated from each other by a distinct distance. Thus, the advantages of using individual fibrous reinforcing strands can be incorporated into a mat structure.10 Such melt-bondable fibers are disciosed in European Patent Application 340,982 published November 8, 1989.
The fibrous reinforcing material can be oriented as desired for advantageous applications of the present invention. That is, the fibrous reinforcing m~l can be ra~domiy distributed, or the fibers and/or strands can be oriented l5 to extend~ along a direction desired for imparting improved strength and tear clwac~istics.
The fibrous reinforcing material can be dlrected such that the majority of the strength in the cross direction can be attributed to the organic polymeric binder. To achieve this, either a high weight ratio of binder to fibrous reinforcing 20 material is employed, such as 10:1; or, the fibrous reinforcing material, usually in the fortn of individual reinforcing strands, is present in only the machine, ~.e., longitudmal, direction of the backing loop.
Referring to the~ various views of the backing of an endless belt of the presçnt invention shown in Figs. 3 to 6 (not shown to scale), it is preferred that 25 the fibrous reinforcing material, particularly the individual reinforcing strands, be present in a coated abrasive bachng construction in a predetermined, i.e., not random, position or array. For example, for the backing loop 30 of Fig. 3, the individual wraps 31 in the layer of reinforcing fibrous strands are oriented to extend in the machine direction of the backing loop 30; Fig. 3 being a 30 representation of the endless, seamless backing loop without any abrasive material or adhesive layers coa~d thereon,~and with a portion of an internal layer of ;
,-, , .

WO93/12911 ~ 86 pc~rJuss2/o933l ~0.. , - .
- 20 - ' " ;
reinforcing strands exposéd.
As shown in Fig. 4, the fibrous reinforcing material is present in two ~`
distinct layers 32 and 33 with solidified organic binder layers 34, 35, and 36 ;
above, between, and below the layers of fibrous reinforcing material 32 and 33.
S One layer (33) is oriented aboYe and separate from the other layer (32) by a layer of organic binder material 35. Layer 33 is a layer of fibrous strands with the wraps 31 in extension in the longitudinal direction of the backing loop. Layer 32 is a layer of a fibrous rdnforcing mat or web. This orientation of the strands in the longitudinal direction of the backing provides advantageous characteristics,10 particularly tensile strength, i.e., resistance to tealing in the longitudinal direction of the backing~loop.
Although not shown in any particular figure, the reinforcing fibrous strands ;
can alternatively be oriented to extend in the cross direction of a coated abrasive backing, or at least to approach the crass direction. Furthermore, for alternative ; ~ ~ 15 embodiments; not- shown in any particular figure, alternate layers of reinforcing strands can be oriented to extend in both the longitudinal and cross direction, ~pectivély, of the coated abrasive backing as a grid, if so desired. A significant - impr~vement in cross tear resistance is realized when the fibers are extended in the cross direction, and segments may be spliced togetha to form segmented backing 20 ~ s.
Refemng to the embodiment of Fig. S, the backing 50 has one layer of fibrous reinforcing mat structure 52 in the internal structure of the backir.g 50.
The embodiment shown in Fig. 5 shows a fibrous reinforcing mat structure with individual parallel fibrous strands 53 incorporated therein. Although not 25 specifically sbown in Fig. 5, the layer of fibrous reinforcing mat structure typically c!onsists of at least two wraps of the reinforcing mat.
Referring to the embodiment of Fig. 6, the backing 60 has three parallel - layers, i.e., planes, 62, 63, and 64 of fibrous reinforcing material. These three - layers 62, 63, and~ 64 are separaled from one another by regions of organic 30 ~ polymi~ binder~material 65 and 66.~ Thesè three layers 62, 63, and 64, generally do not overlap, intedock, or cross one another, and are coated by regions of ,, ,: . : -~. ~
,- . , . , .
, ~

,:- . . ~

Wo 93/12911 ~ L 1 ~ 6 Pcr/lJss2/o933 or~anic binder material 67 and 68 at the surfaces of the bacl~ng. The embodimentin Fig. 6 shows layers 62 and 64 as layers of fibrous mat structure, and layer 63 as a layer of fibrous strands positioned in the machine direction of ti~_ backing loop 60.
The backings of the present invention can further and advantageously for certain applications of the present invention include other additives. For example, incorporation of a toughening agent into the backing will be preferred for certain applications. Preferred toughening agents include rubber-type polymers or plasticizers. The preferred rubber toughening agents are synthetic elastomers.
l0 Preferably, at least an effective amount of a toughening agent is used. Herein, the term "effective amount" in this context refers to an amount sufficient to impartimprovement in flexibility and toughness.
Other materials that can be advantageously added to the backing for certain applications of the present invention include inorganic or organic fillers. Inorganic lS fillers are also known as mineral fillers. A filler is defined as a particulate material, typically having a particle size less than lQ0 micrometers, preferably less than 50 micrometers. The ~IIIer may also be in the form of solid or hollow spheriods, such as hollow glass and phenolic spheroids. Fillers are capable of being dispersed uniformly within the binder material. Examples of useful fillers20 for applications of the present invention include carbon black, calcium carbonate, silica, calcium metasilicate, cryolite, phenolic fillers, or polyvinyl alcohol fillers Typically, a filler would not be used in an amount greater than 70 weight % based on the weight of the make coating, and 70 weigbt % based on the weight of a sizecoating.
2S Other useful materials or components that can be added to the backing for certain applications of the present invention are pigments, oils, antistatic agents, flame retardants, heat stabilizers, ultraviolet stabilizers, internal lubricants, antioxidants, and processing aids. ~xamples of antistatic agents include graphite fibers, carbon black, metal oxides such as vanadium oxide, conductive polymers, 30 humectants and combinations thereof.

WO 93/12911 ~ 8 6 Pcr/us92/o933l ;

- 22 - !
The adhesive layers in the coated abrasive articles of the present invention are formed from a resinous adhesive. Each of the layers can be forrned from the same or different resinous adhesives. Useful resinous adhesives are those that are compatible with the organic polymeric binder material of the backing. Cured 5 resinous adhesives are also tolerant of grinding conditions such that the adhesive layers do not deteriorate and prematurely release the abrasive material.
The resinous adhesive is preferably a layer of a thermosetting resin.
E~camples of useable dtetsetting resinous adheslves suitable for this inventioninclude, without limitation, phenolic resins, aminoplast resins, urethane resins, 10 epoxy resins, acrylate resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, or mixtures thereof. ~ ~
The first and second adhesive layers, referred to in Fig. 2 as adhesive layers 12 and 15, i.e., the make an~l size coats, can preferably contain other 15 m~tterials~that~are commonly utihzed in abrasive articles. These materials, referred to as~addidves, ~include grinding aids, coupling agents, wetting agents, dyes, ~;
pigments, plasticizers, release agents, or combinations thereof. Fillers might also be used ;as~ addit ves in the first and second~ adhesive layers. Fillers or gnnding aids~aré~typically present in no more than an àmount of 70 weight %, for either 20 the~make~ or size coating, based upon the weight of the adhesive. Examples of~usefùl;~fillers include calcium salts, such as calcium carbonate and calcium metasilicate, silica, metals, carbon, or glass.
The third adhesive layer 16 in Fig. 2, i.e., the supersize coat, can preferably include a grinding aid, to enhance the abrading charactenstics of the25 coated- abrasive. Examples of grinding aids include potassium tetrafluoroborate, cryolite, ammonium cryolite, or sulfur. One would not typically use more of a grinding aid than needed for desired results.
- Examples of abrasive material suitable for applications of the present - ~ invention include fused aluminum oxide, heat treau d aluminum oxide, ceramic 30 aluminum~ oxide, silicon carbide, alumina zirconia, garnet, diamond, cubic boron nitridé, or mixtures~ thereof. The term "abrasive material" encompasses abrasive ~,,, ~ , ,~ ,, :
~ . .
-~ - ~, - -wo 93/12911 pcr/uss2/o9331 i grains, agglomerates, or multi-grain abrasive granules. An example of such agglomerates is described in U.S. Patent No. 4,6S2,27S. It is also with the scope of the invention to use diluent erodable agglomerate grains as disclosed in U.S.Pat. No. 5,078,753.
The average particle size of the abrasive grain for advantageous applications of the present invention is at least 0.1 micrometer, preferably at least lOQ
micrometers. A grain size of 100 micrometers corresponds approximately to a coated abrasive grade 120 abrasive grain, according to American National Standards Institute (ANSI) Standard B74.18-1984. The abrasive ~rain can be lO oriented, or it can be applied to the backing without orientation, depending upon the desired end use of the coated abrasive backing.
Alternatively, the abrasive material can be in the form of a preformed sheet material coated with abrasive material that can be laminated to the outer surface of an endless, seamless bachng loop. The sheet material can be from cloth, 15 paper, vulcanized fiber, polymeric film forming material, or the like.
Alternatively, the preformed abrasive coated laminate can be a flexible abrasivemember as disclosed in U.S. Patent No. 4,256,467. Briefly, this abrasive member is made of a non-electrica]ly conductive flexible material or flexible material having a nonelectrically conducting coating. This mærial is formed with a layer 20 of metal in which abrasive material is embedded. The layer of rnetal is adhered to a mesh material.
The support structure used in such methods of mahng the backings of the invention is preferably a drum, which can be made from a rigid rnaterial such assteel, metal, ceramics, or a strong plastic material. The material of which the 25 drum is made should have enough integrity such tha~ repeated endless, seamless loops can be made without any damage to the drum. The drum is placed on a mandrel so that it can be rotated at a controlled rate by a motor. This rotation can range anywhere from 0.1 to 500 revolutions per minute (rpm), preferably l to lO0rpm, depending on the application. ;~
The drum can be unitary or created of segments or pieces that collapse for easy removal of the endless, setmless loop. lf a larFe endless, seamless loop is ..

WO93/1291~ PCr/l~Ss2/0933 . preferred, the drum is typically made of segments for collapsibility and easy removal of the loop. If such a drum is used, the inner surface of the loop may contain slight ridges where the segments are joined and form a seam in the drum.Although it is preferred that the inner surface be generally free of such ridges, S such ridges can be tolcrated in endless, seamless, loops of the present invention in order to simp1ify manufacture, especially with large belts.
The dimensions of the drum generally correspond to the dimensions of the endless,, seamless loops. The circumference of the drum, will generally correspond to the inside circumference of the endless~ seamless loops. The width10 of the endless, seamless loops can be of any value less than or equal to the width of the drum. A single endless, seamless loop can be made on the drum, removed from the drum, and the sides can~ be trimmed. Additionally, the loop can be slitlongitudinally into multiple loops with each having a width substantially less than the original loop.
15 ~ ~ ~ In many instances, it is preferred that a release coating be applied to the .
periphery of the drum befrQe the binder or any of the other components are appliied. This provides for easy release of the endless, seamless loop after thebinder is solidlfied. In most instances, this~reiease coating ~will not become part .

of ~*e endless, seamless loop. If a collapsible ~drum is used in the preparation of 20 a largè endless, seamless loop, such a release liner helps to preven~, or at least ` reduce, the formation of ridges in the inner surface of the loop, as dis~ussed above. Examples of such release coatings include, but are not limited to, silicones, fluorochemicals, vr polymeric films coated with silicones or fluorochemicals. It is also within the scope of this invention to use a second 25 release coating which is plac~d over the final or top coating of the binder. This s,econd release coating is typically present during the solidification of the binder, and can be removed afterwards.
,~
The thermosetting binder material is typically applied in a liquid sta~e or semi-liquid state to the drum. The application of the binder can be by any `
30~ effec~ive~technbuesuch as~spraying,~diecoating, knifecoating, roll coating, curtain~coating, or transfer coating. For these coating techniques, the drum is WO 93/12911 PCr/US92/09331 """ 2116l~8G

typically rotated as~the thermosetting binder is applied. For example, referring to Fig. 7, a thermosetting binder 72 can be applied by a curtain coater 74 set above the drum 76. As the drum 76 rotates, the thermosetting binder 72 is applied to the periphery 77 of the drum 76. It typically takes more than one rotation of the drum 5 to obtain the proper coating of the thermosetting binder, such that the fibrous reinforcing material is fully coated and will be fully surrounded by organic binder material in the final product. The thermosetting binder 72 rnay also be heated to lowa the viscosity and to make it easier to use in the coating process.
It is also within the scope of this invention to use more than one type of 10 binder material for a given backing. When this is done, the two or more types of binder materia1s, e.g., thermosetting binder materials, can be mixed together prior to the coating step, and then applied to the drum. Alteratively, a first binder material, e.g., a thermosetting resin, can be applied to the drum. followed by asecond binder material, e.g., a thennoplastic material. If a thermosetting resin is 15 used in combination with a thermoplastic material, the thermosetting resin may be gelled, or partially cured, prior to application of the thermoplastic material.
For thermosetting resins, the solidification process is actually a curing or polymerization process. The thermosetting resin is typically cured with either time - - ~ or a combination of time and energy. This energy can be in the form of thermal 20 energy, such as heat or infrared, or it can be in the form of radiation energy, such as an ele~tron bearn, ultraviolet light, or visible light. For thermal energy, the oven temperature can be within a range of 30-250C, preferably within a range of75-lSQC. The time required for curing can range from less than a minute to over20 hours, depending upon the particular binder chemistry employed. The amount 25 of energy required to cure the thermosetting binder will depend upon various factors such as the binder chemistry, the binder thickness, and the presence of other material in the backing composition.
The thermosetting binder material is preferably partially solidified or cured before the other components, such as the adhesive coats and the abrasive grain, are 30 applied. The binder matenal can be either partially or fully polymerized or cured while remaining on the drum.
....

WC~ 93/12g11 ~ PCr/US92/09331 The fibrous reinforcing material can be applied to the drum in several maMers. Primarily, the particular method is dictated by the choice of fibrous material. A preferred method for applying a continuous individual reinforcing fibrous strand invoives the use of a level winder. In this method, the drum is S rotated while the reinforcing fibrous strand is initia11y attached to the drum, is pulled through the level winder, and is wound around the drum helically across the width of the drum, such that a helix is forrned in longitudinal extension around the length of the drum. It is preferred that the level winder move across the entirewid* of the drum such that the continuous reinforcing fibrous strand is uniformly 10 applied in a layer across the drum. ln this embodiment, the strand is in a heli~ly wound panern of a plurality of ~ wraps in~ a layer within the organic polymeric binder~material, wlth ach wrap of the strand parallel to and in contact with theprevious wrap of the strand.
If tho level windu does not move across the entire width of the drum, the : ~ ~
- ~ ~ 15 ranforcing fibrous strands can be paced in the backing in a specific portion along ~o~widtb-of the se~lmless, endless loop. In this way, regions in which reinforcing fibrous strands are present in one plane can be sq~ated from each other without overlap. ~ For advantageous strength, howeva, ;the fibrous reinforcing strands are in a continuous layer across the width of the bdt backing.
2 0 ~ The level winder can also contain an orifice such that as the fibrous strand ~p~oceeds through the orifice it is coated with a binder material. The diam~er of the orifice is selected to correspond to the desired amount of binder.
Additionally, it may be preferable to wind two or more different yarns side by side on the level winder. It is also preferable to wind two or more different25 yarns at a time into the bachng. For example, one yarn may be made of fiberglass and another may be polyester.
A chopping gun can also be used to apply the fibrous reinforcing material.
- A chopplng gun projects the fibers onto the resin material on the drum, preferably while the drum is rotating and the gun is held stationary. This method is 30 p~icularly~ suited when the reinforcing fibers are small, i.e., with a length of less millimeters. I f the length~ of the reinforcing fiber is less than S
,.

.

won/l29~ 1 6 ~ 8 G Pcr/uss2/09331 -- 27 - ` `
rnillimeters, the reinforcing fiber can be mixed into and suspended in the binder.
The resulting binder/fibrous material mixture can then be applied to the drum ina similar manner as discussed above for the binder. `
In certain applicadons of the present invention, the binder is applied to a ~ .
5 rotating drum, and the fibrous reinforcing material is then applied. The binder will then typically wet the surfaces of the reinforcing material. In preferr~
applications of the present invention, the fibrous reinforcing material is coated with `
the binder and then the binder/fibrous material is applied to the drum.
If the fibrous material is in the form of a mat or web, such as a nonwoven 10 or woven mat, the mat is applied by directing it from an unwind station and wrapping it around the drum as the drum rotates. Depending upon the particular ;
construction desired, there can be more than one wrap of the fibrous nnat structure around the drum. Preferably, there are at least two wraps of the fibrous mat in each "layer" of the fibrous mat structure. In this way a discreet seam in the layer lS is~avoided.
The fibrous mat structure can be combined with the organic polymeric binder material in several manners. For example, the mat can be applied directlyto the binder material that has been previously applied to the drum, the mat canbe applied to the drum first followed by ti~e binder materialt or the mat and the 20 binder material can be applied to the drum in one operation.
In preferred applications of the present invention, the fibrous mat structure is coated or saturated with the organic polymeric binder material prior to application to the drum. This method is preferred at least because the amount ofbinder material can be more easily monitored. This coating or saturation can be 25 done by any conventional technique such as roll coating, knife coating, curtain coating, spray coating, die or dip coating Referring to Fig. 8, in a preferred method for preparing a preferred backing loop of the present invention, the fibrous mat structure 82 is saturated with the organic polymeric binder material 84 as it is removed from an unwind station30 85. The amount of binder material 84 applied is determined by a knife coater 86, WOg3/12911 ~i'ô686 PCI/US92/09331 - 28 - ' in which a gap 88 in the h~ife coater controls the amount of polymeric binder material 84 applied.
The mat/liquid binder composition (82/84) is then applied to a drum 90 in at least one layer, i.e., such that the mat/liquid binder composition (82/84) isS wrapped completely around the drum at least once. Although the finished backing structwe is seamless, there is a seam in the internal structure of an endless, seamless loop made in this manner. To avoid such a seam, it is preferable to wrap the mat/liquid binder composition (82/84) around the drum 90 at least twice. Thebinder wets the surface of the fibrous mat structure prior to solidification such that 10 upon curing a unitary, endless, seamless, construction is achieved.
If a layer of a continuous individual reinforcing fibrous strand is used as well, the process descnbed above~ can be used in its application. Referring to Fig.
8, the method involves the use of a yarn guide system 91 with a level winder 92 In this method, the drum 90 is rotated while the reinforcing fibrous strand 94 is 15 initially attached to the drum 90, is pulled through the level winder 92, and is wound around the drum 90 helically across the width of the drum, such that the , ~ ~
layer of ~é slrand 94 is no wider than the layer of the mat 82. It is preferred that ~e le~el winder 92 move across the width of the drum such that the continuous reinforcing fibrous strand 94 is uniformly applied in a layer across the width of the 20 mat 82. Thus, the strand 94 is in a helically wound pattern of a plurality of wraps in a layer within the organic polymeric binder material, with each wrap of the strand parallel to and in contact with the previous wrap of the strand Furthermore, the hldividual wraps of the strand 94 are at a constant nonzero angle relative to the parallel side edges of the mat 82. Sufficient uncured thermosetting 25 resin 84 is applied to the~ mat 82 to provide a layer of resin at least above and below the reinforcing material, i~e., on the outer and inner surfaces of the loop Furthermore, there is a layer of resin betweçn the mat 82 and layer of fibrous strand 94, if sufficient resin is used.
lt is also within the scope of this invention to make non-unlform endless, 30 seamless b~àcking~loops. ln non-uniform backing loops there will be at least two distina~regions where the compositlon and/or amount of materials are not uniform .~
: ~ :

;::

WO 93/12gl 1 Pcr/uss2/os33~

This nqn-uniformity can either be throughout the length of the backing loop, thewidth of the backing loop or both the length and width of the backing loop. The composition non-uniformity can be attributed to either the binder material, the fibrous reinforcing material or any optional additives. The non-uniformity can also 5 be associated with different materials in different regions of the backing loop or the lack of a material in certain regions of the backing loop.
Figs. 10 through 12 illustrate three embodiments of non-uniforrn backing loops. Referring to Fig. 10, the backing loop 100 has three regions 101, 102, 103. The center of the backing loop 102 has a reinforcing yarn, whereas the 10 adjacent regions 101 and 102 do not have reinforcing yarns. Regions 101 and 102 are made solely of binder material. The resulting backing loop will tend to havemore flexible edges. Refemng to Flg. 11, the backing loop 110 has three regions,111, 112 and 113. Center 112 of the backing loop is made essentially of only thebinder, the regions adjacent to center region 111 and region 113 comprise binder15 and rèinforcing material. Referring to Fig. 12, backing loop 120 has two regions 121 and 122. In region 122, the backing loop comprises a binder2 reinforcing strands and a reinforcing mat. In region 121, the bacl~ng loop comprises only a binder and reinforcing fibers. There are many combinations of binder, reinforcing strands, reinforcing mats, additives and the amounts of such materials.
20 The particular selection of these materials and their configurativn is dependent upon the desired application for the coated abrasive made using the backing loop.
For instance, the backing loop described above and illustrated in Fig. 10 may have applications for an abrading operation where it is desired to have flexible edges on the coated abrasive. The bacl~ng loop described above and illustrated in Fig. 1125 may have applications for abrading operations in which it is desired to have strong edges to prevent the edges from tearing.
There are many different methods to make a non-uniform backing loop.
In one method, the level winder only winds the fibrous strands in certain regions of the drum. In another method, a chopping gun places the reinforcing material 30 in certain regions. In a third method, the reinforcing yarns are unwound from a station and wound upon the drum in only certain regions. In still another wog3/l2gll i~ i i i3 b 8 6 Pcr/uss2/093 - 30 - !
approach, the binda material is only placed or coated on certaun regions of the drum. It is also within the scope of the invention to use a combination of all of the different approaches.
There are several ways in which the optional additives can be applied. The 5 method of application depends upon the particular components. Preferably, any additives are dispersed in the binder prior to the binder being applied to the drum.
In some situations, however, the addition of additive to the binder results in either a thiltotropic solution or a solution that has too high a viscosity to process. In such a situation, the additive is preferably applied separately from the binder 10 ma~ial. For example, the binder material can be applied to the drum first, and while it ls in a "tacky" stue, additives can be applied. Preferably, the drum with the binder material rotates while the additive is either drop coated onto the drum or projected onto the drum. With either method, the additive can be uniformly appbed acwss the wld~th of ~he drum or concentrated in a specific area.
15 ~ Altna~ivdy, the additive(s) can be applied to the fibrous reinforcing material, and ~the fibiadditive~s) combination can be applied to the drum.
To~make the endless, seamless bachng loops of the present inventionl there ~should~be~enough binder material present to completely wet the surface of the fibrous réinforcing material and addltives. If necessary, an additional layer of20 binder material can be applied after these components are added to the binder.
~Addi~onally, there should be enough binder matenal present such that the bindermaterial seals the surfaces of the backing and provides relatively "smooth" and uniform surfaces, as discussed previously.
Fig. 9 illustrates an alternative embodiment of a process for forming an 25 endless, seamless bachng of the present invention. This process is similar to that shown in Fig. 8, but uses an alternative support structure. In this embodiment the .
process uses a conveyor unit 100. This particular procedure illustrates the general method of making a backing of an endless, seamless loop utilizing a thermosetting binder material, although a thermoplastic material could also be used. The ';
backing~is formed on a sleeve 102, i.e."n the form of a belt. The sleeve 102 is -.
ferably a stainless steel sleeve. The s~ainless steel sleeve 102 can be coated - .
. :.
,.
.

W0 93/12g~ S 8 6 Pcr/Us92/o9331 ~;

with a silicone release liner, i.e., material, on the outer surface of the sleeve for easy removal of the endless, seamless loop formed. The sleeve 102 can be of any size desired. A typical example is in the form of a belt 0.4 mm thick, 10 cm wide, and 61 cm in circumference. This sleeve 102 is typically mounted on a two S idler, cantilevered, drive system 104 that rotates the sleeve 102 at any desired rate The drive system 104 consists of two drive idlers 106 and 108, a motor 110 and a belt drive means 112.
The procedures described herein with respect~ to forming an endless, seamless loop f:or a coated abrasive belt on a drum, apply also to the forming of 10 a loop on~ this conveyor unit 100. For example, analogously to the method discussed in Fig. 8, a nonwoven web 82 is sa~urated with a liquid organic bindermaterial; g4 by~ means of a knife coater 86. The resulong saturated material, i.e., ~ .
matl!iquid binder composition (82/84) is then preferably wrapped twice around the outer surfa~e, i.e., periphery~, of the sleeve~ 102 as it rotates on the drive system 15 ~ at~a rate, for example, of 2 revoludons~per minute (rpm). A single fibrous s~and 94 can then be wrappeo over the saturated nonwoven web, i.e., ~maVliquid binder composldon (82/84) ~by means of a yarn guide system91~with~a~levd winder 92 that moves across the face of the drive idler 108 as the 91oevo; 102 lOlates on the drive system 104. The sleeve 102 typically rotates at a 20~ ~spoed of 50 ~pm. This results in a backing with a distinct layer of fibrousrunforcing ~strands with a spacing of 10 st~ands per cm of width. This strand spacing can be changed by increasing or decreasing the rate of rotation of the sleeve or by increasing or decreasing the speed of the yarn guide. Aher the binder is cured, the sleeve can be removed and the endless, seamless backing loop 25 9qlala~ f~rom the sleeve.
, Alternative applications of the adhesive and abrasive material are within the scope of this invention. For example, an abrasive slurry consisting of a plurality of abrasive grains dispersed in an adhesive can be prepared. This abrasive slurry can be applied ~to the backing~in a variety o f manners, and the adhesive solidified 30 ~ T)lo ablasive~material can~ also be app!ied using a preformed abrasive coated lan~inate. This~laminate consists of a sheet of material coated with abrasive grains.

, ~ ,, -WO 93/12911 Pcr/uss2/o9331 The sheet of material can be a piece of cloth, polymeric film, vulcanized fiber,paper, nonwoven web such as that known under the trade designation "Scotch-Brite". Alternatively, the laminate can be that disclosed in U.S. Patent No. 4,256,467. The laminate can be applied to the outer surface of the backing 5 of the present invention using: any of the adhesives discussed above;
thermobonding; a pressure sensitive adhesive; or mechanical fastening means, such as a hook and loop means, as is disclosed in U.S. Patent No. 4,609,S81.
An alternative embodiment of the present invention comprises an article wherein the abrasive layer is an endless, seamless loop which is attached to a 10 preformed material, the preformed material being adhered to the inside surface of the loop. This embodiment allows for reuse of the preformed material. The abrasive loop, which will norm~lly wear OUt with use, may be replaced. ln this embodiment, the preformed material may have a seam, but the abrasive loop is seamless.
In preparation of a coated abrasive belt of the present invention, the backing loop can be installed a~ound two drum rollers, which are connected to a motor for rotating the backing. Altematively, the backing can be installed around one drum roller, which is connected to a motor for rotating the backing Preferably, this drum roller can be the same as the drum used in the preparation20 of the endbss, seamless backing loop. As the backing rotates, the adhesive layers or abrasive slurry are applied by any conventional coating technique such as ~nife coating, die coating, roll coating, spray coating, or curtain coating. Spray coating is p~eferred for certain applications.
If an abrasive slurry is not used, i.e., if the abrasive material is applied 25 after the first adhesive layer is applied, the abrasive grains can be electrostatically de~osited onto the adhesive layer by an electrostatic coater. The drum roller acts as the ground plate for the electrostatic coater. Alternatively, the abrasive grains can be applied by drop coating.
Preferably, the first adhesive layer is solidified, or at least partially 30 solidified, and a second adhesive layer is applied. The second adhesive layer can be applied by any conventional method, such as roll coating, spray coating, or '.:

WOg3/12gl~ 6 8 1~ Pcr/US92/09331 curtain coating. The second adhesive layer is preferably applied by spray coating.
The adhesive layer(s) can then be fully solidified while the backing is still on the ;
drum rollers. Alternatively, the resulting product can be removed from the drum rollers prior to solidification of the adhesive layer(s).
If the components forrning the backing of the invention include a thermoplastic material, they could be injection molded. Alternatively, there are - -several different methods that can be used to apply a thermoplastic binder to a hub, i.e., drum roller. For example, a solvent can be added to the thermoplasticbinda such that the therrnoplastic can flow. ln this method the thermoplastic 10 binder can be applied to the hub by any technique such as spraying, knife coating, ;
roll coating, die coating, curtain coating, or transfer coating. The thermoplastic ~ ,'r, bind~ is then solidified by a drymg process to remove the solvent. The drying conditions will depend upon the particular solvent employed and the particular ~ `
~ermop astic binder material employed. Typical drying condibons include ~ .
15 ~ ~mpaa~res~within a range of 15-200C, preferably 30-100C.
Allcrnatively, the therrnoplastic binder can be heated above its softening ~ `
point, and preferably above its melting point, such that it can flow. In this method, the thermoplastic binder material can be applied to the hub by any technbue ~such as spraying, knife coating, roll coatingj die coating, curtain 20 coating, or transfer coadng. The thermoplastic material is then solidified by cooling.
In a third method, the thermoplastic binder matenal c~n be applied in a solid or semi-solid form. This method is preferred for certain applications of the present invention. Typically, a segment of a therrnoplastic material is cut and 25 applied~to~ the drum. The fibrous reinforcing material and any additives or other components are then applied to the hub. A second segment of a thermoplastic material is then applied over the fibrous reinforcing material. The hub/thermoplastic material are then heated to above the softening point, and ;~ p~ erably;~ to above the melting point, of the thermoplàstic binder material such 30~ that~the~mo~plasdc binder flows and fuses all the components of the backing.~The thermoplastic binder material is then cooled and resolidified. ~`
:, ~ , - : :, ~ " ' ;: `
~ ` ., "~ ' ~:.

WO93/12911 `~ 86 PCr/US92/09331 ~

The~re are various alternative and acceptable methods of injection moldîng the coated abrasive backing of the present invention. For example, the reinforcing fibers can be blended with the thermoplastic material prior to the injection molding step. This can be accomplished by blending the fibers and thermoplastic in a 5 heated extruder and extruding pellets.
If tnis method is used, the reinforcing fiber size or length will typically range from 0.5 millimeter to 50 millimet~rs, preferably from l millimeter to 25 millimeters, and more preferably from 1.5 millimeter to 10 millimeters.
Alternatively, and preferably, so as to form a distinct layer of reinforcing 10 material, a woven mat,~a nonwoven mat, or a stitchbonded mat of the reinforcing fiber can be placed into the mold. The thamoplastic material and any optional components an ~e injection molded to fill the spaces between the reinforcing fibers. In this aspect of the invention, the reinforcing fibers can bc oriented in a desired direction. Additionally, the rdnforcing fibers can be continuous fibers 15 with a length determined by the size of the mold.
Af~r the~ bachng is injection molded, then the make coat, abrasive grains, and size~caat can be typically applied by conventional techniques to form the ecatod a lasive articles of the present ~nvention. Using these methods~described, t~e mold ~shape and dimensions generally correspond to the desired dimensions of ~, i,, ~- 20 the bachng of the coated abrasive article.
Elastomeric binders can be solidified either via a curing agent and a curing or polymedzation process, a vulcanization process or the elastomeric binder can be coated out of solvent and then dried. During processing, the temperatures should not exceed the melting or degradation temperatures of the fibrous 25 reinforcing mate ial.
In certain applications of the invention, a material such as cloth, polymeric film, vulcanized fiber, nonwoven, fibrous reinforcing mat, paper, etc~, treated ;; versions thereof, or combinations thereof can be laminated to the endless, seamless backing of the invention. Alternatlvely, a coated abrasive article as described in 30 U.S.~Patent No.~4,256~467 can~be used as~a laminate.; A laminate such as this can ~e us~ to further~ improve the belt trachng, wear properties, and/or adhesive p opQties. It can be used to impa economy and ease in manufacture, strength ,, ~ ~ ., .
, " ' WO 93/12911 ~ 1 1 ~ 6 8 6 pcr/us92/o9331 to the end-product, and versatility. The material can be laminated tO either theouter, i.e., grinding, surface of the belt, or to the inner surface.
The present invention will be further described by reference to the ~-~
following detailed examples.
;
Genera1 Infolmation The amounts of material deposited on the backing are reported in -~
grams/square meter (g/m2), although these amounts are referred to as weights; all`~`
rados are based upon these weights. The following designa~ions are used l0 throughout the examples.

PETlNW a spunbonded~ polyester nonwoven mat approxi-mately 0.127 mm thick and weighed approximately 28 g/m2. lt was purchased from the Remay Co~poration, Old Hickory, TN, under the trade -"~
designation "Remay."

PET polyethylene terephthalate. - ~
.:
PVC polyvinyl chloride.
PU polyurethane.

ERl a diglycidyl ether of bisphenol A epoxy resin commercially available from Shell Chemical Co., Houston, IX, under the trade designation "Epon 828."
, , j ' ,' ECA a polyamide cunng agent for the epoxy resin, commercially available from the Henkel Corporation, Gulph Mill, PA, under the trade designation "Versamid 125."

,: : .

.~, ., WO93/12911 `~ 86 PCr/U592/09331 - 36- ' ER2 an aliphatic diglycidyl ether ~poxy resin commercially available from the Shell Chemical Co., Houston, TX, under the trade designation "Epon 871."

S SOL an organic solvent, having the trade designation "Aromatic 100," ~-commercially available from Worum Chemical Co., St. Paul, MN.

GEN an arnidoamine resin, known under the trade designation "Genamid 747", from Henkel Cosporation. -.. `.
Procedure I for Prepariny an Endless. Seamless Backin~
This procedure illustrates the general method of making a backing of an endless, seamless loop utilizing a thern oset binder material. The backing was formed on an aluminum hub having a diameter of 19.4 cm and a circumference 15 of 61 cm. The aluminum hub had a wall thickness of 0.64 cm and was installed on a 7.6 cm mandrel rotated by a DC motor capable of rotating from 1 to 40 `
revolutions per minute (rpm). Over the periphery of the hub was a 0.13 millimeter thick silicone coated polyester film, which acted as a release surface.
This silicone coated polyester film was not part of the backing. The final `~
20 dimensions of the loop were 10 cm wide by 61 cm long.
A no~woven web approximately 10 cm wide was saturated with a therRloset binder material by means of a hlife coater wi~h a gap set at 0.3 mm. The ~esulting saturated material was wrapped twice around the hub as the hub rotatedat approximately S rpm. Next, a single reinforcing fibrous strand was wrapped 25 over ~he saturated nonwoven web by means of a yarn guide system with a level winder that moved across the face of the hub at 2.5 cm per minute The hub was rotating at 23 rpm. This resulted in a backing with a distinct layer of fibrous strands with a spacing of 9 strands per cm of width. The strand spacing was ~
changed by the increase or decrease in the rate of rotation of the hub or the ; `
30 increase or decrease in the speed of the yarn guide. Next, a third layer of the :-nonwoven web, which was not saturated with binder, was wrapped on top the : `
reinforcing fibrous strands. This nonwoven layer absorbed the excess thermoset ~ `

Wo 93~1291 1 .~ ; Pcr/uss2/os331 ~
. . .

binder material. Quartz element IR heaters placed 20 cm from the hub were used to gel the resin. This took 10-15 minutes with the construction at 94C. ~

~Qçedure II for Preparin~ an Endless, Seamless BackiD~ `;
This procedure illustrated the general method of making a backing of an endless, seamless loop utilizing a thermoplastic binder material. The backing was formed on the same aluminum hub as described in the Procedure I. The hub also contained the silicone coated polyester release film. A sample of 0.13 mm thick thermoplastic binder material was cut into strips that were 10 cm wide. These -10 thennoplastic strips were wrapped around the hub two times. Next9 a single layer -of a nonwoven web was wrapped around the hub on top of the thermoplastic binder materiak Over the nonwoven was wrapped a reinforcing fibrous strand in a manner similar to that described in Procedure I. Then an additional thermoplastic strip was wrapped around the hub over the reinforcing fibrous 15 strands. ~Finally another layer of silicone coated polyester film was wrappedaround the hub over the thermoplastic film. Again the silicone coated polyester film was not part of the backing. The resulting construction and hub was placed in an oven and heated to the point where the thermoplastic binder material fusedthe nonwoven and the reinforcing materials together. For PVC and PU, fusion occurs at~ 218C during a period of 30 minutes. Next, the construction and hub was removed from the oven and cooled. The top layer of the silicone polyester film was removed.

General Pro~edure îor Makin~ the Coa~ed Abrasive The backing for each example was installed on the aluminum hub/mandrel assembly as described in "Procedure I for Prepanng the Backing," as the hub rotated at 40 rpm. A make coat, i.e., first adhesive layer, was applied by an air spray gun to the outer surface of the backing loop. It took between 30 to 40 seconds to spray the make coat, i.e~., first adhesive layer, onto the backing. The make coat was 70% solids in solvent (comprising 10% "Polysolve" and 90%
water) and consisted of 48% resole phenolic resin and 52% calcium carbonate fillér. ~"Polysolve" 1984PM water blend containing 15% water and 85 % propylene :

:

WO 93/12911 f G ~ 8 ~ PCl/US92/0933 -- 38 ~
glycol monomethyl ether is available from Worum Chemical Co. in St. Paul, MN.
The make coat adhesive wet weight was 105 g/m2. Next, grade 80 heat treated aluminum oxide was electrostatically coated onto the make coat with a weight of 377 g/m2. The hub acted as a ground for the electrostatic coating process and a S hot plate was placed directly below the hub. For this electrostatic coating process, the abrasive grain was placed on the hot plate. The hub containing the backing/make coat was rotated at 40 rpm and the mineral was coated in 30 secondsover the backing/make coat to achieve full coverage of the abrasive grain. Next,the resulting coated abrasive article was thermally precured in a box oven for 90 10 minutes at 88C. A size coat was then sprayed in the same manner as was the make coat over the abrasive grains and precured make coat. The size coat adhesive wet weight was 120 g/m2. The size coat, i.e., second adhesive layer, consisted of the same formulation as the make coat. The resulting coated abrasive product received a thermal cure of 90 minutes at 88C and a final cure of 10 hours 15 at 100C. Prior to tesbng according to the Particle Board Test, the coated abrasive was flexed, i.e., the abrasive coating was uniformly and directionally craclced, using a 2.54 cm supported bar.
'~
icle Board Test The coated abrasive belt (10 cm x 61 cm) was installed on a take-belt type grinder. The workpiece for this test was 1.9 cm x 9.5 cm x 150 cm industrial grade, 20.4 kg density, low emission urea-formaldehyde par~icle board available from Villaume lndustnes, St. Paul, MN. Five workpieces were initially weighed.
Each workpiece was placed in a holder with the 9.5 cm face extending outward.
A 15.3 kg load was applied to the workpiece. The 9.5 cm face was abraded for 30 seconds. The workpiece was reweighed to determine the amount of particle board removed or cut. The total cut of the five workpieces were recorded. This sequence was repeated S times for each workpiece for a total of 12.~ minutes of grinding. The control example for this test was a 3M 761D grade 80 "Regalite"
30 Resin Bond Cloth coated abraslve, commercially available f~om the 3M Company,St. Paul, MN. The grinding results can be found in Table 1. The percentage of WO 93/12911 PCI`~US92/09331 ~ ~ ~16~86 - 39 - , control was determined by: dividing the cut associated with the particular example by the cut associated with the control example, times 100.

E~KamDl~s 1 throu~jh 10 S The backing for this set of examples was made according to "Procedure I
for Preparing the Backing" and the coated abrasives were made according to the ~General Procedure for Making the Coated Abrasive." The nonwoven mat was PETlNW and the thermoset binder material consisted of 40% ERl, 40~ ECA, and 20% ER2. The therrnoset binder material was diluted to 95% solids with 10 SOL. The ratio of resin to nonwoven web was lS:1. For each example a different ranfordng fibrous strand was utilized.

~xample 1 For example 1 tho rdnforcing fiber was 1000 denier pol~ester multifilament - 15 yarn, commercially available from Hoechst Celanese, Charlotte, NC, under the ~de ~;d~tion T-786." The bachng contained a strand spacing of appro~im tely 9 strands/cm.
;' Exampb 2 ;
20 ~ Por example 2 the reinforcing fiber was 28 gauge chrome bare wire, - - commeraally available from Gordon Company, Richmond, IL, under the catalog number 1475 (R275103. The backing contained a strand spacing of approximately 9 st~ands/cm.

25 E~imple 3 For example 3 the reinforcing fiber was a nng spun polyester cotton count 12.5, commercially available from West Point Pepperell, under the trade designation "T-310, " 12.3/1, 100% polyester, Unity Plant Lot 210. The backing contained approximately 12 strands/cm.

WO 93/12sl1 Pcr~us92/o933l 8 ~

~ample 4 For example 4 the reinforcing flber was 1800 denier polyester multifilament yarn, commercially available from Hoechst Celanese, Charlotte, NC, under the ;
trade designation "T-786." The backing contained approximately S strands/cm.
, ~
Example S
For example S the reinforcing fiber was 55 denier polyester multifilament `~
yarn, commercially available from Hoechst Celanese under the trade designation ~T-786." The backing contained approximately 43 strands/cm.
~;~.,, Example 6 For example 6 the relnforcing fiber was 550 denier polyester multifilarnent~ ~ ~yarn, commercially available from Hoechst Celanese under the trade designation ~ r "T-786." The backing contained approximately 18 strands/cm. ^
',~
Exam~le 7 For exarnple 7 the reinforcing fiber was l9S denier aramid multifilament yarn, commercially availab!e from DuPont, Wilmlngton, DE, under the trade designation "Kevlar 49." The backing contained approximately 12 strands/cm. ~-Example 8 For example 8 the reinforcing fiber was 250 denier polypropylene `
multifilament yarn, commercially available from Amoco Fabric and Fibers Co., Atlan~a, GA, under the trade designation "1186." The bacldng contained 25 approximately 12 strandslcm.

Example 9 For example 9 the reinforcing fiber was a ring spun cotton yarn~ cotton count 12.S, commercially available from West Point Pepperell, West Point, GA, ~``
under the trade designation "T-680." The backing contained approximately 12 ~`
strands/cm.

: . ' WO 93tl291 1 ~ 8 ~ Pcr/us92/09331 r ~
~ 41 ~
Example 10 For example 10 the reinforcing fiber was a fiberglass roving 1800 yield, commercially available form Manville Corp., Denver, CO, under the trade `
designadon "Star Roving S02, K diameter. N The backing contained approximately 5 6 strands/cm.

Examples 11 through 15 The backing for this set of examples was made according to "Procedure I
for Preparing the Backing," with slight modifications as indicated. The coated 10 abrasives were made according to the "General Procedure for Making the CoatedAbrasive." Thethermosetbindermaterialconsisted of 40% ER1, 40% ECA, and 20% ER2. The thermoset binder material was diluted to 95% solids with SOL.
The reinforcing fiber for this set of examples was 1000 denier multifilament ~
polyester yarn, commercially available from the Hoechst Celanese, Charlotte, NC, ~ -15 under the trade designadon "Trevira T-786." There were 9 reinfor~ing ~;
strands/cm. For each example a different nonwoven mat was utilized.
: ~-Example l l ;
For example 11 the nonwoven mat was a spunbonded polypropylene that 20 was approximately 0.2 millimeter thick with a weight of 43 g/m2, commerciallyavailable *om Remay lnc., Old Hickory, TN, under the trade designation "T~
Style 3121. There was no third layer of nonwoven mat in this example. The ratio of thermose~ binder-to nonwoven was 15:1.

For Example 12 the nonwoven mat was a spunbonded polyester that was approximately 0.3 millimeter thick with a weight of 72 g/m2, commercially available from Remay Inc. under the trade designation "Remay" Style 2405. `
There was no third layer of nonwoven mat in this example. The ratio of thermoset30 binder to nonwoven was l0~

. -WO 93/1291 1 ` ~ PCr/USs2/09331 - 42 - ' Example 13 For Example 13 the nonwoven mat was a spunbonded polyester that was approximately 0.11 millimeter thick with a weight of 21 g/m2, commercially available from Remay Inc. under the trade designation "Remay" Style 2205. The 5 ratio of thermoset binder to nonwoven was 14:1.

xample 14 For F~xample 14 the nonwoven mat was an aramid based nonwoven with ~-approximately 2.5 cm long fibers. The nonwoven was approximately 0.1 ~.
10 millimeter thick with a weight of 9 g/m2, commercially available from -International Paper, Purchase, NY, under the trade designation "8000032/0418851." The ratio of thermoset binder to nonwoven was 27:1. ; `

~xample lS ~ -lS For Example 15 the nonwoven mat was a continuous spun fiberglass mat that was approximately 0.25 millimeter thick with a weight of 42 g/m2, ~ ~-commercially available from Fibre Glast Inc., Dayton, OH, under the trade designation "Plast" 260. The ratio of thermoset binder to nonwoven mat was 10:1. ';.
Examples 16 through 20 The backing for this set of exarnples was made according to "Procedure 1 for Preparing the Backing" and the coated abrasives were made according to the "General Procedure of Mal~ng the Coated Abrasive." The nonwoven matenal was 25 PETlNW. The reinforcing fiber for this set of examples was lQ00 denier mul~filament polyester yarn, commercially available from Hoechst Celanese under the trade designation "Trevira T-786." There were approximately 9 reinforcing strandslcm. For each example a different thermoset material was employed.

30 Exam~le 16 The thermoset binder materia1 for Example 16 consisted of 20% silica fi11er, 68% isophthalic polyester resin, commercially available from Fibre Glast ,~

WO 93/12911 2 1 1 6 S 8 6 Pcr/us92to933l ., .

Corp., under the trade designation "Plast #gO," and 12% polyglycol commercially available from Dow Chemical Co., Midland, MI, under the trade designation "E400. " This example did not contain the third layer of the nonwoven. The ratioof thermoset binder to nonwoven was l5:l.
S
13xample 17 `
The thermoset binder material for Example 17 consisted of 40% silica filler, 30% ERl, and 30% fatty amidoamine resin, trade name "Genamid 490,"
commercially available from Henkel Corp., Gulph Mills, PA. The ratio of lO thermoset binder to nonwoven was l5 ~
'.~';
Example l 8 The thermoset binder material for Example 18 consisted of 20% calcium ~
carbonate filler, 32% ERl, 32% ECA, and 16% ER2, diluted to 95% solids with -~`
15 SOL. The ratio of thermoset binder to nonwoven was 14:1.

~xample 19 ` ~
The thermoset binder material for Example 19 consisted of 10% chopped ~;fiberglass (1.5 millimeter in length), commercially available from the Fibre Glas~
Corp. under the trade designation "Plast #29," 36% ER1, 36% ECA, and 18%
ER2, diluted to 95 % solids with SOL. The ratio of thermoset binder to nonw~ven was 15~

Example 20 The thermoset binder material for Example 20 consisted of 40% silica filler, 15% graphite, 22.5% ER1, and 22.5% fatty amidoamine resin, trade name "Genamid 490," commercially available from Henkel Corp~ This example did not ~`
contain the third layer of the nonwoven. The ratio of thermoset binder to nonwoven was 20: l . `

3~

W0 93/l2g~ 8 ~ P~r/US92/09331 :

les 21 throu~ 25 The backing for this set of examples was made according to "Procedure Il for P~ring the Backing" and the coated abrasive were made according to the "Gencral Procedure for Making the Coated Abrasive." The nonwoven material S was PEl lNW. The reinforcing fibrous strand for this set of examples was lO00 ~ ;
denier muldfilamentpolyester yarn, commercially available from Hoechst Celanese under the trade designatdon "Trevira T-786." For each example a different thermoplasdc binder matenal was employed.

lO Example 21 The thermoplastic binder material for this Example 21 consisted of O.ll millimeter thick plasticized PVC film, matte finish, commercially available fromthe Plastics Film Corp. of America, Lemont, IL. The reinforcing fiber in the backing was present at a strand spacing of approximately 6 strands/cm. The ratiolS of thermoplastic binder to nonwoven was 30: l .

~amplo 22 ;
The thermoplastic binder material for Example 22 consisted of O.ll ~mil~ eter thick plasticized PVC film, matte finish, commercially available from20 the Plastics Film Corp. of America. The reinforcing fiber in the backing was ~plesent at approximately 6 strands/cm. In this example there was no nonwoven present. ~`

Example 23 The thermoplastic binder material for Example 23 consisted of O.l1 millimeter thick plasticized PVC film, matte finish, commercially available fromthe Plastics FIlm Corp. of America. There was no reinforcing fibrous strands `
present. The backing construction was altered slightly from "Procedure II for Preparing the Backing." The backing was prepared by applying one layer of the 30 thermoplastic binder material, one layer of the nonwoven, followed by a second ~`
layer of the the~oplastic binder material, a second layer of a nonwoven and ; :

~: ' WO g3/1291 1 2 1 1 6 6 8 6 PCr/USs2/0933l finally a third layer of the thermoplastic binder material. The ratio of thermoplastic binder to nonwoven was 15:1.

Example 24 S The thermoplastic binder material for Example 24 consisted of 0.11 millimeter thick plasticized PVC film, matte finish, commercially available fromthe Plastics Film Corp. of America. There was no reinforcing fibrous strands present. The backing construction was altered slightly from "Procedure II for Preparing the Backing. " The backing was prepared by applying two layers of the 10 thermoplastic binder material, one layer of the nonwoven, followed by a layer of a fiberglass scrim and finally a third layer of the thermoplastic binder material. ;
The fiberglass scrim had I yarn/cm in the cross belt direction and 2 yarns/cm inthe belt length direction. The f1berglass yarn was 645 yield multifilament E g!ass, commerciallyavailablefromBayexCorp.,St.Catherine's,Ontario,Canada. The 15 ratio of therrnoplastic binder to nonwoven was 30~
.
Example 25 The thermoplastic binder material for Example 25 consisted of 0.13 millimeter thick clear polyurethane film, commercially available from the Stevens 20 Elastomeric Corp., Northampton, MA, under the trade designation "HPR625FS.n The reinforcing fibrous strands in the backing were present at approximately 6 strandstcm. The ratio of thermoplastic binder to nonwoven was 30:1.

Example 26 thrQy~h 36 lhe coated abrasive backings of these examples illustra~e various aspects of the invention. The hub to make the bacl~ng was the same as the one described in "Procedure I for Preparing the Backing." The coated abrasives were made according to the "General Pro~edure for Making the Coated Abrasive."

30 E~ample 26 A thermoset binder was prepared that consisted of 40% ERl, 40% ECA, and 20% ER2. The thermoset binder was diluted to 95% solids with SOL. The .:

WO 93~12911 Pcr/us92/o933l thermoset binder was knife coated (0.076 millimeter thick layer) onto a O.OSl - -millimeter polyester film purchased from the ICI Film Corp., Wilmington, DE, under the trade designation "Melinex 475." Three layers of this thermoset binder/film composite were wrapped onto the hub ~,vith the thermoset binder facing 5 outward from the hub. The therrnoset binder was then cured for 30 minutes at -88C.
~: . . ,;
Example 27 ~ ~`
A fiberglass scrim, as described above in Example 24 was saturated via a lO knife coater with the thermoset binder of Example 26. The knife coater gap was set to approximately 0.25 millimeter. Two layers of this thennoset/fiberglass scrim composite'were wrapped onto the hub. The thermoset binder was then cured for 30 minutes at 88C. The ratio of thermoset binder to scrim was 3~
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lS xamyle~28 `
The backing for Example 28 was made in a similar manner to that of E~;ample l except for the following changes. A layer of fiberglass scrim, the same fiberglass scrim as describeid in Example 24, was inserted between the last layer of the nonwoven and ~e reinforcing fibrous strands. There was no layer of 20 nonwovon placed on top of the layer of reinforcing fibrous strands. The ratio of ~ -~
thermoset binder to nonwoven was 13 Examplç 29 -The backing fior Example 29 was made in a similar manner to that of 25 Example 1 except for the following changes. There was no reinforcing fibrous strand. There were four layers of the thermoset binder/nonwoven composite wrapped around the hub. The ratio of thermoset binder to nonwoven was 8:1.

Example 30 The bachng for Example 30 was made in a similar manner to that of Example 1 except that a layer of an untreated A weight paper was wrapped around ` '..

WO 93/12911 2 1 1 6 IS 8 li PCr/US92/09331 the hub prior to the f1rst layer of the thermoset binder/nonwoven. This A weightpaper, of mass 70g/m2, remained a part of the backing. ~`
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Example 31 The backing for Example 31 was made in a similar manner to that of Example 1 except for the following changes. The 2.54 cm strip thermoset binder/nonwoven composite was wrapped around the drum twice helically, at an angle of approximately five degrees. A third layer of nonwoven was not used. ~;

10 ~xample 32 The backing for Example 32 was made in a similar manner to that of Exarnple 21 except that a 2.54 cm strip of thermoplastic binder/nonwoven were -helically wound onto the drum at an angle of approximately five degrees.

15 ExamDle 33 Backing was made in a similar manner to that of Example 1, except the third layer of nonwoven was not included. A 0.13 millimeter polyurethane film was fused to tke outside surface of the backing. Film and method of fusing was same as used in Example 25. The coated abrasive was made according to the0 HGeneral Procedure for malcing the Coated Abrasive".
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Example 34 Backing was made in a similar manner to that of Example 1, except the third layer of nonwoYen was not included. The abrasive was attached to the 25 bacldng using an acrylate pressure sensitive adhesive (PSA), RD 41-4100-1273-0, available from 3M Company? St. Paul, MN. PSA coat weight was 1.6 grams (dry ` -, weight) per square meter. Abrasive backing laminated to the backing was 3M
21 lK "Three-M-ite" "Elek-tro-cut, " grade 80, commercially available from the 3M
Company, St. Paul, MN.

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WO g3/12911 t~ ~ ~ G~&6 Pcr/uss2/os33l Example 35 `
Backing was made in a similar manner to that of ~xample 1, except the third layer of nonwoven was not included. While t;he binder was still uncured, alayer of abrasive coat backing was laminated on top of the backing. Abrasive S backing laminated to the backing was 3M 211K "Three-M-iten "Elek-tro-cut," ~ `
grade 80, commercially available ftom the 3M Company, St. Paul, MN. The binder was then cured in the normal fashion.

Example 36 --Backing was made in a similar manner to that of Example 1, except the -third layer of nonwoven was not included and a different binder resin was used.
The binder was a UV curable syslem made up on 98% "Mhoromer" 6661-0 ~ `
(diruetbane dimethyacylate), commercially available from Rohm Tech lnc., Malden, MA; 2% "Irgacure" 651, commercially available from Ciba-Geigy;
15 H~, NY. After the backing was formed, it was cured under a 300 watts ~
~pcr inch VV light for 20 seconds. The coated abrasive was made according to the ~ -"Gene~al Procedure for making the Coated Abrasive".
;' ' ExamDll~s 37 and 38 ~-Two backings were made in a similar manner to that of Example 1, except -the~ third layer of nonwoven was not included and a different binder resiD was used. In Example 37, only continuous fiberglass filament yarns were used, whereas in Example 38 two different reinforcing yarns were used side-by-side as the layer of reinforcing yams. The fiberglass filament yarn was available from 25 Owens-Coming Fiberglass Corp., Toledo, Ohio. The continuous fiberglass Blament yarn used was ECG 75 0.7Z 1/0 finish 603, stock number 57B54206, having 30 filarnents per inch. The second backing was formed 50/50 side-by-side with one half being the same fiberglass filament as use in Example 37, the second half being made using l0~0 denier polyester yun described in Ex~ample 1. The 30 binder resin used was 37.5 % urethane resin (known under the trade designation ~"BL-16" from Unirogal Chemical~Corp.); 12.5 % of a solution of 35 % methylene -~diaminel65 ~% 1-methoxy-2-propyl acetate; 16.5 % ERl; 16.S % ER2; and 17.0 :;

WOgJ/III ~ 86 PCI/U59~/09331 ~

% of GEN. The backings were each coated with a standard calcium carbonate filled resole phenolic make resin, which was partially cured in known manner. -Grade 120 cetamic aluminum oxide, commercially available from 3M under the ttade designation "Cubitronn, was fotmed into agglomerate abtasive particles in S the manner of U.S. Pat. No. 4,799,939 to form agglomerates of average particlesize of 750 micrometers. These agglometates were drop coated onto the partia11y cured make coating by conventional techniques. A standard calcium catbonate .filled resole phenolic tesin size coating was utilized and the resulting structure given a standard cure and flex. Tensile tests were performed as with previous 10 examples, with the results presented in Table 2.
Samples from each backing~ of Examples 37 and 38 were subjected to bending ~around sharp edges, and machine direction tensile tests rerun. The following bending cases were used~
Case 1: the backing was folded In on itself until the back sides were - touching.
Case 2: ~ the sample was folded around a 0.32 cm diameter rod.
Case 3: the sample was folded around a 0.64 cm diarneter rod. =
Case 4: the sample was folded around a 1.27 cm diameter rod. ~^-T}ie~-tensile values (~glcm) in machine direction were as follows: - ~
~ ~, .....
Case #
no flexing 1 2 3 4 Example 37 52 7.5 30 40 56 ~ ~ -Example 38 63 58 59 59 57 25Tesf ResuIts Particle Board Test The Particle Board test results are shown in Table 1. One belt of each type was tested. A sample passed this test if the backing did not break. Only Example ~ -23 Hfailed," probably because there were no reinforcing yarns in the longitudinal `
30 direction. These results indicate that usefu1 abrasive articles can be made from any of the ~several embodiments~ of ~this~ invention. -. . - ~.

WO 93/1291 1 ~ 8 PCr/~lS92J09331 Table 1: Particle Board Test :-.
Backi~u Cut fiom Workpiece Example ~hL~ as a % ~f Control S ~, 5~0 103 2 1 130 ~3

4 775 1 10 16 600 ~10 19 ~06 133 21 581 ~5 ~69 117 2~ 404 87 ~8 ~31 99 31 541 9~
32 54~ 101 ~6 678 1 14 :

Tensile Test Procedure and Results Strips of dimensions 2.5 cm by 17.8 cm were taken from endless, seamless backings of Examples 1-36. The strips were taken from the backings in two ~:

WO 93/12911 PCI`/US92/09331 `21161~86 `

directions: Strips were taken in the machine direction (MD) and from the cross -direction (CD) (normal to the machine direction).
These strips were tested for tensile strength using a tensile testing machine known under the trade designation "Sintech", which measured the amount of force ~;

5 required to break the strips. The machine has two jaws. Each end of a strip was ~-placed in a jaw, and the jaws moved in opposite directions until the strips broke.
In each test, the length of the strip between the jaws was 12.7cm and the rate at :-which the jaws moved apart was 0.5 cm/sec. ln addition to the force required to break the strip, the percent stretch of the strip at the break point was determined .
-10 for both the machine and cross direction samples. " % stretch" is defined as l(final ;
length minus original length)/original length], and this resul~ multiplied by 100.
Data are presented in Table 2.
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W0931}~g11 ~u~8~ PCr/US92/09331 Table 2: Tensile Test Results :::
Mlacbune Direction C ross I~urection Tens~e Tensile E~xalnple Value Value S N u mbff~r ~kg/c m) % Stretch (kg/c m) % Stretch 1 53.0 10.1 10.7 1.2 2 41 3.9 8.0 1.7 3 34 8.5 14.6 3.0 4 52 10.8 12.5 2.1 27 10.5 11.4 2.6

6 63 17.2 10.0 1.6

7 41 1.7 12.9 2.8 ~-~

8 23 8.1 14.6 3.1 lS 9 22 2.2 8.4 2.1 134 3.2 9.8 1.2 11 49 10.8 8.6 12.0 12 63 13.0 13.4 3.1 13 54 11.1 8.9 0.8 ; -14 50 9.9 11.2 1.3 lS 45 6.0 15.0 1.3 16 60 19.6 4.1 1.9 :~
17 68 19.9 8.4 1.5 ~ -18 58 16.3 10.7 2.2 19 74 18.8 12.7 2.6 -.
18.7 8.2 0.8 21 48 21.2 5.9 5.1 22 49 23.3 5.7 6.7 23 12 27.0 8.0 14.0 24 29 24.2 8.6 16.0 44 20.3 ~.3 19.0 26 1~ 5.1 21.3 15.0 27 28 17.0 12.0 10.4 28 73.6 13.4 11.6 3.2 2g 22 ~0 23.4 5.2 61 21.7 13.2 2.9 31 59 3.2 6.9 7.4 32 41 2.6 7.3 14.5 1 33 37 14.5 ~.4 18.0 34 38 15.0 11.6 26.0 4.5 13.6 18.0 36 54.5 2.7 7.5 0.9 : 45 :~;, ,`
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Wo 93/12911 pcrtuss2/os331 - 53 - : :;
The invention has been described with reference to vanous specific ~nd .
preferred embodiments and techniques. It should be understood, however, that many variations and modifications can be made while remaining within the scope of the inven~ion.
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:

Claims

CLAIMS:

1. A coated abrasive backing characterized by having:
(a) 40-99 weight percent of an organic polymeric binder material, based upon the weight of the backing; and (b) an effective amount of a fibrous reinforcing material;
wherein the organic polymeric binder material and fibrous reinforcing material together comprise a flexible composition in the form of an endless, seamless loop; the flexible endless, seamless backing loop having:
(i) a length with generally parallel side edges; and (ii) at least one layer of fibrous reinforcing material engulfed within the organic polymeric binder material.

2. The backing of claim 1 further characterized by the endless, seamless loop including a plurality of noninterlocking layers of fibrous reinforcing material engulfed within the organic polymeric binder material.

3. The backing of claim 1 further characterized by the layer of fibrous reinforcing material having a layer of one continuous fibrous strand wrapped generally in the form of a helix in longitudinal extension around the length of the backing loop.

4. The backing of claim 3 further characterized by having the layer of one continuous fibrous strand being individual wraps of the strand at a constant, nonzero angle relative to the parallel side edges of the backing loop.

5. The backing of claim 3 further characterized by having a layer of a fibrous mat structure engulfed within the organic polymeric binder material.

6. The backing of claim 1 further characterized by the layer of fibrous reinforcing material being a layer of a fibrous mat structure.

7. The backing of claim 1 further characterized by the layer of fibrous reinforcing material being a layer of a fibrous mat structure with individual parallel fibrous strands incorporated therein.

8. The backing of claim 1 further characterized by being non-uniform throughout its length, width, or both its length and width, the non-uniformity occurring in one or more of (a) the composition of the binder;
(b) the amount of the binder; and (c) the amount of the reinforcing material.

9. The backing of claim 32 further characterized by having a filler in the organic polymeric binder, in which the amount, composition, and location of the filler is non-uniform in said binder.

10. A coated abrasive including the backing of any one of the preceeding claims.