Claims
- 1. A coatable, thermally curable binder precursor solution comprising:
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance of the solution comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups or with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR12## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 300; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.
- 2. A solution in accordance with claim 1 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.
- 3. A solution in accordance with claim 1 wherein said thermally curable resin is selected from the group consisting of phenolic resins, urea-aldehyde resins, and mixtures thereof.
- 4. A solution in accordance with claim 3 wherein said thermally curable resin is a phenolic resin selected from the group consisting of novolak, resole, and resolated novolak resins.
- 5. A solution in accordance with claim 1 wherein at least one functional group reactive with the pendant methylol groups comprises an --NH-- group.
- 6. A solution in accordance with claim 1 wherein said reactive diluent has a molecular weight of at most about 300.
- 7. A solution in accordance with claim 1 wherein said reactive diluent has a molecular weight of at most about 600.
- 8. A solution in accordance with claim 5 wherein said reactive diluent has a molecular weight of at most about 300.
- 9. A solution in accordance with claim 4 wherein said phenolic resin is a resole.
- 10. A solution in accordance with claim 1 which further includes water in an amount sufficient to turn the resultant solution permanently milky in appearance.
- 11. A solution in accordance with claim 1 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to 100:1.
- 12. A solution in accordance with claim 1 wherein said thermally curable resin and reactive diluent are present in a weight ratio ranging from about 2:1 to about 100:1.
- 13. A solution in accordance with claim 1 wherein said solution further includes abrasive particles.
- 14. A solution in accordance with claim 1 wherein R.sup.1 is 2-hydroxyethyl, R.sup.2 and R.sup.3 are linked to form an ethylene bridge and R.sup.4 is hydrogen.
- 15. A solution in accordance with claim 1 wherein X is O, Y is NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is butyl and R.sup.4 is hydroxyethyl.
- 16. A solution in accordance with claim 1 wherein X is O, Y is NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is ethyl, and R.sup.4 is butyl.
- 17. A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR13## wherein R.sup.6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.
- 18. A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR14## wherein x is an integer ranging from about 2 to about 20.
- 19. A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR15## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.
- 20. A solution in accordance with claim 1 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the formula ##STR16## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.
- 21. A cured version of the solution of claim 1.
- 22. An abrasive article comprising a plurality of abrasive grains dispersed and adhered within a binder, the binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR17## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said abrasive article is a nonwoven abrasive the molecular weight of the poly (oxyalkylene) amine is less than about 300; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.
- 23. The abrasive article of claim 22 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.
- 24. The abrasive article of claim 22 wherein said functional group reactive with the pendant methylol groups is --NH--.
- 25. An abrasive article in accordance with claim 22 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 is 2-hydroxyethyl, R.sup.2 and R.sup.3 are linked to form an ethylene bridge, and R.sup.4 is hydrogen.
- 26. An abrasive article in accordance with claim 22 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is butyl and R.sup.4 is hydroxyethyl.
- 27. An abrasive article in accordance with claim 22 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is ethyl and R.sup.4 is butyl.
- 28. An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR18## wherein R.sup.6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.
- 29. An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR19## wherein x is an integer ranging from about 2 to about 20.
- 30. An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR20## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.
- 31. An abrasive article in accordance with claim 22 wherein said reactive diluent is a poly(oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR21## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.
- 32. An abrasive article in accordance with claim 22 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon nitride, and mixtures thereof.
- 33. An abrasive article in accordance with claim 22 wherein said coatable, thermally curable binder precursor solution further comprises a thermal curing catalyst.
- 34. An abrasive article in accordance with claim 33 wherein said thermal curing catalyst is benzoyl peroxide.
- 35. An abrasive article in accordance with claim 22 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.
- 36. An abrasive article in accordance with claim 22 wherein said article is a bonded abrasive.
- 37. A coated abrasive article comprising a backing upon which an abrasive coating comprising abrasive grains and binder is attached, said binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR22## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.
- 38. The coated abrasive article of claim 37 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.
- 39. The coated abrasive article of claim 37 wherein said thermally curable resin is a phenolic resin selected from the group consisting of resole, novolak, and resolated novolak resins.
- 40. The coated abrasive article of claim 37 wherein said phenolic resin is a resole.
- 41. The coated abrasive article of claim 37 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to about 100:1.
- 42. The coated abrasive article of claim 37 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon carbide, and mixtures thereof.
- 43. The coated abrasive article of claim 37 wherein said binder precursor solution further comprises a thermal curing catalyst.
- 44. The coated abrasive article of claim 43 wherein said thermal coating catalyst is benzoyl peroxide.
- 45. The coated abrasive article of claim 42 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.
- 46. The coated abrasive article of claim 37 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 is 2-hydroxyethyl, R.sup.2 and R.sup.3 are linked to form an ethylene bridge, and R.sup.4 is hydrogen.
- 47. The coated abrasive article of claim 37 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is butyl and R.sup.4 is hydroxyethyl.
- 48. The coated abrasive article of claim 37 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is ethyl and R.sup.4 is butyl.
- 49. The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR23## wherein R.sup.6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.
- 50. The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR24## wherein x is an integer ranging from about 2 to about 20.
- 51. The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR25## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.
- 52. The coated abrasive article of claim 37 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR26## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.
- 53. A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating over the abrasive grains, wherein at least one of the make or size coatings is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR27## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.
- 54. A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating, over the abrasive grains, wherein said backing has at least one of a saturant coating, a presize coating, or a backsize coating, wherein at least one of said saturant coating, said presize coating, or said backsize coating is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR28## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.
- 55. A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising:
- (a) adhering abrasive grains to the fibers of the fibrous mat with a coatable, thermally curable binder precursor solution, said solution comprising a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water, and reactive diluent, thus producing a coated mat, said thermally curable resin being the reaction product of a non-aldehyde and an aldehyde, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR29## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said reactive diluent is a poly(oxyalkylene) amine, its molecular weight is less than about 300; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; and
- (b) subjecting the coated mat to conditions sufficient to cure the binder precursor solution.
- 56. A method in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR30## wherein R.sup.6 is an alkyl group having 1 to 4 carbon atoms and n and m are integers ranging from 0 to 20.
- 57. A solution in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR31## wherein x is an integer ranging from about 2 to about 20.
- 58. A solution in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR32## wherein a, b, and c are integers, the sum of a plus c ranges from 1 to 5, and b ranges from 0 to 20.
- 59. A solution in accordance with claim 55 wherein said reactive diluent is a poly (oxyalkylene) amine selected from the group consisting of compounds represented by the general formula ##STR33## wherein m, n, and o are integers greater than zero such that the sum of m, n, and o ranges from about 5 to about 30, and wherein A is a triol initiator.
- 60. A method in accordance with claim 55 further comprising applying a size coating to the abrasive coated mat of step (b) and curing the size coating.
- 61. A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising:
- (a) combining 30-95% solids solution of a thermally curable resin, the balance comprising water, with reactive diluent to form a coatable, thermally curable binder precursor solution, at a temperature below that necessary to cure the coatable, thermally curable binder precursor solution, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR34## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000, with the proviso that if said reactive diluent is a poly(oxyalkylene) amine, its molecular weight is less than about 300; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000;
- (b) adding abrasive grains to the coatable, thermally curable binder precursor solution;
- (c) coating the abrasive-filled, coatable, thermally curable binder precursor solution onto at least a portion of the fibers of a lofty, open fibrous mat; and
- (d) heating the abrasive coated mat of step (c) to a temperature sufficient to cure the coatable thermally curable binder precursor solution.
- 62. A method of making a bonded abrasive article, said method comprising:
- (a) combining a coatable, thermally curable binder precursor solution comprising a 30-95% solids solution of a thermally curable resin, the balance comprising water, the resin having a plurality of pendant methylol group and made from the reaction product of a non-aldehyde and an aldehyde, and a reactive diluent with abrasive grains to form a mixture, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR35## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000; and
- (b) subjecting the mixture of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.
- 63. A method in accordance with claim 62 which further comprises introducing said abrasive grains, said binder precursor solution, and said reactive diluent into a mold prior to step (b).
- 64. A method of making a coated abrasive article, said method comprising:
- (a) coating a backing with a coatable, thermally curable binder precursor solution comprising a 30-95% solid solution of a thermally curable resin, the balance comprising water, abrasive grains, and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR36## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000,
- thereby providing a coated backing; and
- (b) subjecting the coated backing of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.
- 65. A method in accordance with claim 64 wherein prior to step (a) water is added to the binder precursor solution in an amount sufficient to turn the resultant solution permanently milky in appearance.
- 66. A method of making a coated abrasive article comprising the steps of:
- (a) applying a first coatable, thermally curable binder precursor solution to at least one major surface of a backing to form a make coating, the coatable, thermally curable binder precursor solution comprising a thermally curable resin and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR37## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time;
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- C) poly (oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and
- D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000;
- (b) subjecting the make coating to conditions sufficient to partially cure the make coating;
- (c) applying abrasive grains to the partially cured make coating of step (b) to form an abrasive coating;
- (d) applying a second coatable, thermally curable binder precursor solution which is the same as or different than the first coatable, thermally curable binder precursor solution to form a size coating over the abrasive coating of step (c); and
- (e) subjecting the structure of step (c) to a temperature sufficient to cure the first and second coatable, thermally curable binder precursor solutions.
- 67. A coatable, thermally curable binder precursor solution in accordance with claim 1 which further includes an ethylenically unsaturated monomer.
- 68. A cured version of the coatable, thermally curable binder precursor solution of claim 14.
- 69. An abrasive article in accordance with claim 22 wherein said coatable, thermally curable binder precursor solution includes an ethylenically unsaturated monomer.
- 70. The coated abrasive article of claim 36 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
- 71. The method of claim 55 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
- 72. The method of claim 62 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
- 73. The method of claim 64 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
- 74. A coatable, thermally curable binder precursor solution comprising:
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance of the solution comprising water; and
- (b) a reactive diluent;
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups or with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR38## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes.
- 75. A solution in accordance with claim 74 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.
- 76. A solution in accordance with claim 74 wherein said thermally curable resin is selected from the group consisting of phenolic resins, urea-aldehyde resins, and mixtures thereof.
- 77. A solution in accordance with claim 76 wherein said thermally curable resin is a phenolic resin selected from the group consisting of novolak, resole, and resolated novolak resins.
- 78. A solution in accordance with claim 74 wherein at least one functional group reactive with the pendant methylol groups comprises an --NH-- group.
- 79. A solution in accordance with claim 77 wherein said phenolic resin is a resole.
- 80. A solution in accordance with claim 74 which further includes water in an amount sufficient to turn the resultant solution permanently milky in appearance.
- 81. A solution in accordance with claim 74 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to 100:1.
- 82. A solution in accordance with claim 74 wherein said thermally curable resin and reactive diluent are present in a weight ratio ranging from about 2:1 to about 100:1.
- 83. A solution in accordance with claim 74 wherein said solution further includes abrasive particles.
- 84. A solution in accordance with claim 74 wherein R.sup.1 is 2-hydroxyethyl, R.sup.2 and R.sup.3 are linked to form an ethylene bridge and R.sup.4 is hydrogen.
- 85. A solution in accordance with claim 74 wherein X is O, Y is NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is butyl and R.sup.4 is hydroxyethyl.
- 86. A solution in accordance with claim 74 wherein X is O, Y is NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is ethyl and R.sup.4 is butyl.
- 87. A cured version of the solution of claim 1.
- 88. An abrasive article comprising a plurality of abrasive grains dispersed and adhered within a binder, the binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR39## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes.
- 89. The abrasive article of claim 88 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.
- 90. The abrasive article of claim 88 wherein said functional group reactive with the pendant methylol group is --NH--.
- 91. The abrasive article in accordance with claim 88 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 is 2-hydroxyethyl, R.sup.2 and R.sup.3 are linked to form an ethylene bridge, and R.sup.4 is hydrogen.
- 92. An abrasive article in accordance with claim 88 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is butyl and R.sup.4 is hydroxyethyl.
- 93. An abrasive article in accordance with claim 88 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is ethyl and R.sup.4 is butyl.
- 94. An abrasive article in accordance with claim 88 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon nitride, and mixtures thereof.
- 95. An abrasive article in accordance with claim 88 wherein said coatable, thermally curable binder precursor solution further comprises a thermal curing catalyst.
- 96. An abrasive article in accordance with claim 95 wherein said thermal curing catalyst is benzoyl peroxide.
- 97. An abrasive article in accordance with claim 88 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.
- 98. An abrasive article in accordance with claim 88 wherein said article is a bonded abrasive.
- 99. A coated abrasive article comprising a backing upon which an abrasive coating comprising abrasive grains and binder is attached, said binder formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent;
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR40## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1 R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes.
- 100. The coated abrasive article of claim 99 wherein said non-aldehyde is phenol and said aldehyde is formaldehyde.
- 101. The coated abrasive article of claim 99 wherein said thermally curable resin is a phenolic resin selected from the group consisting of resole, novolak, and resolated novolak resins.
- 102. The coated abrasive article of claim 99 wherein said phenolic resin is a resole.
- 103. The coated abrasive article of claim 99 wherein said thermally curable resin and said reactive diluent are present in a weight ratio ranging from about 1:1 to about 100:1.
- 104. The coated abrasive article of claim 99 wherein said abrasive grains comprise flint, garnet, aluminum oxide, alumina zirconia, diamond, silicon carbide, cubic boron nitride, silicon carbide, and mixtures thereof.
- 105. The coated abrasive article of claim 99 wherein said binder precursor solution further comprises a thermal curing catalyst.
- 106. The coated abrasive article of claim 105 wherein said thermal coating catalyst is benzoyl peroxide.
- 107. The coated abrasive article of claim 99 wherein said binder further comprises a component selected from the group consisting of fillers, coupling agents, surfactants, wetting agents, plasticizers, fibers, dyes, pigments, grinding aids, and mixtures thereof.
- 108. The coated abrasive article of claim 99 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 is 2-hydroxyethyl, R.sup.2 and R.sup.3 are linked to form an ethylene bridge, and R.sup.4 is hydrogen.
- 109. The coated abrasive article of claim 99 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is butyl and R.sup.4 is hydroxyethyl.
- 110. The coated abrasive article of claim 99 wherein X is O, Y=NR.sup.3 R.sup.4, R.sup.1 and R.sup.3 are hydrogen, R.sup.2 is ethyl and R.sup.4 is butyl.
- 111. A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating over the abrasive grains, wherein at least one of the make or size coatings is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR41## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes.
- 112. A coated abrasive article comprising a backing, a make coating over at least one major surface of the backing, a layer of abrasive grains over the make coating, and a size coating, over the abrasive grains, wherein said backing has at least one of a saturant coating, a presize coating, or a backsize coating, wherein at least one of said saturant coating, said presize coating, or said backsize coating is formed from a coatable, thermally curable binder precursor solution comprising the reaction product of
- (a) a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water; and
- (b) a reactive diluent,
- wherein said thermally curable resin is the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, and wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehyde, and wherein said reactive diluent is selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR42## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes.
- 113. A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising:
- (a) adhering abrasive grains to the fibers of the fibrous mat with a coatable, thermally curable binder precursor solution, said solution comprising a 30-95% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance comprising water, and reactive diluent, thus producing a coated mat, said thermally curable resin being the reaction product of a non-aldehyde and an aldehyde, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR43## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes, and
- (b) subjecting the coated mat to conditions sufficient to cure the binder precursor solution.
- 114. A method in accordance with claim 113 further comprising applying a size coating to the abrasive coated mat of step (b) and curing the size coating.
- 115. A method of making nonwoven abrasive articles of the type comprising a lofty, open, fibrous mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive grains and a binder, said method comprising:
- (a) combining 30-95% solids solution of a thermally curable resin, the balance comprising water, with reactive diluent to form a coatable, thermally curable binder precursor solution, at a temperature below that necessary to cure the coatable, thermally curable binder precursor solution, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR44## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- (b) adding abrasive grains to the coatable, thermally curable binder precursor solution;
- (c) coating the abrasive-filled, coatable, thermally curable binder precursor solution onto at least a portion of the fibers of a lofty, open fibrous mat; and
- (d) heating the abrasive coated mat of step (c) to a temperature sufficient to cure the coatable thermally curable binder precursor solution.
- 116. A method of making a bonded abrasive article, said method comprising:
- combining a coatable, thermally curable binder precursor solution comprising a 30-95% solids solution of a thermally curable resin, the balance comprising water, the resin having a plurality of pendant methylol groups and made from the reaction product of a non-aldehyde and an aldehyde, and a reactive diluent with abrasive grains to form a mixture, the reactive diluent having at least one functional group independently reactive with the pendant methylol groups and said aldehyde, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR45## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- (b) subjecting the mixture of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.
- 117. A method in accordance with claim 116 which further comprises introducing said abrasive grains, said binder precursor solution, and said reactive diluent into a mold prior to step (b).
- 118. A method of making a coated abrasive article, said method comprising:
- (a) coating a backing with a coatable, thermally curable binder precursor solution comprising a 30-95% solid solution of a thermally curable resin, the balance comprising water, abrasive grains, and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR46## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- thereby providing a coated backing; and
- (b) subjecting the coated backing of step (a) to conditions sufficient to cure the coatable, thermally curable binder precursor solution.
- 119. A method in accordance with claim 118 wherein prior to step (a) water is added to the binder precursor solution in an amount sufficient to turn the resultant solution permanently milky in appearance.
- 120. A method of making a coated abrasive article comprising the steps of:
- (a) applying a first coatable, thermally curable binder precursor solution to at least one major surface of a backing to form a make coating, the coatable, thermally curable binder precursor solution comprising a thermally curable resin and reactive diluent, the resin having a plurality of pendant methylol groups, and being the reaction product of a non-aldehyde and an aldehyde, said non-aldehyde selected from the group consisting of ureas and phenolics, wherein said reactive diluent has at least one functional group which is independently reactive with said pendant methylol groups and with said aldehydes, said reactive diluent being selected from the group consisting of
- A) compounds selected from the group consisting of compounds represented by the general formula ##STR47## and mixtures thereof wherein X=O or S and Y=--NR.sup.3 R.sup.4 or --OR.sup.5, such that when X=S, Y=NR.sup.3 R.sup.4, each of R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 is a monovalent radical selected from the group consisting of hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and with the provisos that:
- (i) said compound contains at least one --NH and one --OH group or at least two --OH groups or at least two --NH groups;
- (ii) R.sup.1 and R.sup.2 or R.sup.1 and R.sup.3 can be linked to form a ring structure; and
- (iii) R.sup.1, R.sup.2, R.sup.3, R.sup.4 and R.sup.5 are never all hydrogen at the same time; and
- B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, and nitro alkanes;
- (b) subjecting the make coating to conditions sufficient to partially cure the make coating;
- (c) applying abrasive grains to the partially cured make coating of step (b) to form an abrasive coating;
- (d) applying a second coatable, thermally curable binder precursor solution which is the same as or different than the first coatable, thermally curable binder precursor solution to form a size coating over the abrasive coating of step (c); and
- (e) subjecting the structure of step (c) to a temperature sufficient to cure the first and second coatable, thermally curable binder precursor solutions.
- 121. A coatable, thermally curable binder precursor solution in accordance with claim 74 which further includes an ethylenically unsaturated monomer.
- 122. A cured version of the coatable, thermally curable binder precursor solution of claim 84.
- 123. An abrasive article in accordance with claim 88 wherein said coatable, thermally curable binder precursor solution includes an ethylenically unsaturated monomer.
- 124. The coated abrasive article of claim 98 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
- 125. The method of claim 113 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
- 126. The method of claim 116 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
- 127. The method of claim 118 wherein said coatable, thermally curable binder precursor solution further includes an ethylenically unsaturated monomer.
Parent Case Info
This application is a continuation-in-part of parent application Ser. No. 07/823,998, filed Jan. 22, 1992, now abandoned and is related to application Ser. No. 07/823,861, filed concurrently with the parent of this application.
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Date |
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228856 |
Jul 1987 |
EPX |
1501331 |
Feb 1978 |
GBX |
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Continuations (1)
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Number |
Date |
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Parent |
823998 |
Jan 1992 |
|