Claims
- 1. A coated abrasive article comprising
- (a) a support member having a front surface and a back surface, said support member optionally being saturated with a saturant, and said back surface of said support member optionally having a backsize layer;
- (b) abrasive granules;
- (c) a first layer of a bond system which serves to bond said abrasive granules to front surface of said support member;
- (d) optionally at least one size layer overlying said first layer; and
- (e) optionally at least one supersize layer overlying said size layer;
- wherein at least one of said saturant, said backsize layer, said first layer, said size layer, and said supersize layer comprises
- (a) a cured alkali metal hydroxide catalyzed phenolic resin; and
- (b) reaction residue with said alkali metal hydroxide catalyzed phenolic resin of an amount of at least one ammonium-based salt sufficient to color stabilize said cured resin, with the proviso that said ammonium-based salt is essentially free of ammonium boron tetrafluoride.
- 2. The coated abrasive article according to claim 1 wherein said ammonium-based salt is NH.sub.4 AlF.sub.4.
- 3. The coated abrasive article according to claim 1 wherein said ammonium based salt is represented by the general formula
- (NH.sub.4,M,M')AlF.sub.6,
- wherein M and M' are cations which may be the same or different and are selected from the group consisting of NH.sub.4.sup.+, Li.sup.+, Na.sup.+, and K.sup.+.
- 4. The coated abrasive article according to claim 1 wherein said ammonium-based salt is selected from the group consisting of ammonium chloride, ammonium bifluoride, dibasic ammonium citrate, tribasic ammonium citrate, ammonium dihydrogen phosphate, and diammonium hydrogen phosphate.
- 5. The coated abrasive article according to claim 1 wherein said cured alkali metal hydroxide catalyzed phenolic resin contains a colorant.
- 6. The coated abrasive article according to claim 1 wherein said abrasive granules are comprised of a material selected from the group consisting of fused alumina, co-fused alumina-zirconia, silicon carbide, flint, garnet, diamond, silicon nitride coated silicon carbide, cubic boron nitride, sintered alpha-alumina-based ceramic and combinations thereof.
- 7. A coated abrasive article comprising
- (a) a support member having a front surface and a back surface, said support member optionally being saturated with a saturant, and said back surface of said support member optionally having a backsize layer;
- (b) abrasive granules;
- (c) a first layer of a bond system which serves to bond said abrasive granules to said front surface of said support member;
- (d) optionally at least one size layer overlying said first layer; and
- (e) optionally at least one supersize layer overlying said size layer;
- wherein at least one of said saturant, said backsize layer, said first layer, said size layer, and said supersize layer comprises
- (a) a cured alkali metal hydroxide catalyzed phenolic resin; and
- (b) reaction residue with said alkali metal hydroxide catalyzed phenolic resin of an amount of at least one ammonium-based salt sufficient to color stabilize said cured resin, wherein said salt is selected from the group consisting of:
- (i) an ammonium-based salt having the formula
- NH.sub.4 AlF.sub.4 ;
- (ii) ammonium-based salts represented by the general formula
- (NH.sub.4, M, M')AlF.sub.6,
- wherein M and M' are cations which may be the same or different and are selected from the group consisting of NH.sub.4.sup.+, Li.sup.+, Na.sup.+, and K.sup.+ ; and
- (iii) ammonium-based salts selected from the group consisting of ammonium chloride, ammonium bifluoride, dibasic ammonium citrate, tribasic ammonium citrate, ammonium dihydrogen phosphate, and diammonium hydrogen phosphate.
- 8. The coated abrasive article according to claim 7 wherein said alkali metal hydroxide catalyzed phenolic resin contains a colorant.
- 9. The coated abrasive article according to claim 7 wherein said abrasive granules are composed of a material selected from the group consisting of fused alumina, co-fused alumina-zirconia, silicon carbide, flint, garnet, diamond, silicon nitride coated silicon carbide, cubic boron nitride, sintered alpha-alumina-based ceramic and combinations thereof.
- 10. A three-dimensional, low density abrasive article comprising
- (a) a three-dimensional, low density web structure;
- (b) abrasive granules; and
- (c) a bond system which serves to bond said abrasive granules to said web structure,
- wherein said bond system comprises
- (a) a cured alkali metal hydroxide catalyzed phenolic resin; and
- (b) reaction residue with said alkali metal hydroxide catalyzed phenolic resin of an amount of at least one ammonium-based salt sufficient to color stabilize said cured resin, with the proviso that said ammonium-based salt is essentially free of ammonium boron tetrafluoride.
- 11. The three-dimensional, low density abrasive article according to claim 10 wherein said ammonium-based salt is NH.sub.4 AlF.sub.4.
- 12. The three-dimensional, low density abrasive article according to claim 10 wherein said ammonium-based salt is represented by the general formula
- (NH.sub.4,M,M')AlF.sub.6,
- wherein M and M' are cations which may be the same or different and are selected from the group consisting of NH.sub.4.sup.+, Li.sup.+, Na.sup.+, and K.sup.+.
- 13. The three-dimensional, low density abrasive article according to claim 10 wherein said ammonium-based salt is selected from the group consisting of ammonium chloride, ammonium bifluoride, dibasic ammonium citrate, tribasic ammonium citrate, ammonium dihydrogen phosphate, and diammonium hydrogen.
- 14. The three-dimensional, low density abrasive article according to claim 10 wherein said cured alkali metal hydroxide catalyzed phenolic resin contains a colorant.
- 15. The three-dimensional, low density abrasive article according to claim 10 wherein said abrasive granules are comprised of a material selected from the group consisting of fused alumina, co-fused alumina-zirconia, silicon carbide, flint, garnet, diamond, silicon nitride coated silicon carbide, cubic boron nitride, sintered alpha-alumina-based ceramic, calcium carbonate, silica, pumice, and combinations thereof.
- 16. A three-dimensional, low density abrasive article comprising
- (a) a three-dimensional, low density web structure;
- (b) abrasive granules; and
- (c) a bond system which serves to bond said abrasive granules to said web structure,
- wherein said bond system comprises
- (a) a cured alkali metal hydroxide catalyzed phenolic resin; and
- (b) reaction residue with said alkali metal hydroxide catalyzed phenolic resin of an amount of at least one ammonium-based salt sufficient to color stabilize said cured resin, wherein said salt is selected from the group consisting of:
- (i) an ammonium-based salt having the formula
- NH.sub.4 AlF.sub.4 ;
- (ii) ammonium-based salts represented by the general formula
- (NH.sub.4,M,M')AlF.sub.6,
- wherein M and M' are cations which may be the same or different and are selected from the group consisting of NH.sub.4.sup.+, Li.sup.+, Na.sup.+, and K.sup.+ ; and
- (iii) ammonium-based salts selected from the group consisting of ammonium chloride, ammonium bifluoride, dibasic ammonium citrate, tribasic ammonium citrate, ammonium dihydrogen phosphate, and diammonium hydrogen phosphate.
- 17. The three-dimensional, low density article according to claim 16 wherein said alkali metal hydroxide catalyzed phenolic resin contains a colorant.
- 18. The three-dimensional, low density article according to claim 16 wherein said abrasive granules are comprised of a material selected from the group consisting of fused alumina, co-fused alumina-zirconia, silicon carbide, flint, garnet, diamond, silicon nitride coated silicon carbide, sintered alpha-alumina-based ceramic, calcium carbonate, silica, pumice, and combinations thereof.
Parent Case Info
This is a continuation of application Ser. No. 07/480,018 filed Feb. 13, 1990, now U.S. Pat. No. 5,110,320.
US Referenced Citations (20)
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0058262 |
Aug 1982 |
EPX |
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JPX |
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Non-Patent Literature Citations (3)
Entry |
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D. B. V. Parker, "The Effect of Catalysts on the Thermal Stability of Phenolic Resins," (Mar. 1957), Royal Aircraft Establishment Technical Note No. Chem. 1299. |
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Continuations (1)
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Number |
Date |
Country |
Parent |
480018 |
Feb 1990 |
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