In specific embodiments, superabrasive particles include cubic boron nitride and diamond particles. These superabrasive particles can be natural (e.g. natural diamond) or synthetic (e.g. cubic boron nitride and synthetic diamond) products. The superabrasive particles may have a blocky shape associated with them or alternatively, a needle-like shape. The superabrasive particles may be surface coated or not surface coated. In an embodiment, a blend of superabrasive particles and conventional abrasive particles (e.g. alumina, silicon carbide, ceria, and silica) can be used.

The abrasive particles can have a particular shape, such as a rod, a triangle, a pyramid, a cone, a solid sphere, a hollow sphere, or the like. Alternatively, the abrasive particles can be randomly shaped.

The abrasive particles can be in a beneficial size range, conform to a beneficial size distribution, or a combination thereof. In an embodiment, the abrasive particles can have an average particle size of not less than 1 micron, such as at least 2 micron, at least 3 micron, at least 5 micron, at least 10 micron, at least 15 micron, at least 20 micron, or at least 25 micron. In an embodiment, the average particle size can be not greater than 500 micron, such as not greater than 400 micron, not greater than 300 micron, not greater than 200 micron, not greater than 150 micron, or not greater than 125 micron. The average particle size can be within a range comprising any pair of the previous upper and lower limits. In an embodiment, the abrasive particles can have an average particle size not less than 5 micron to not greater than 250 micron, such as 10 micron to 200 micron, such as 15 micron to 150 micron, such as 20 micron to 125 micron.

Binder Composition—Make Coat or Slurry Coat

As stated previously, a layer of polymeric binder composition 115 can be disposed in direct contact with the polymeric front coat composition 111. In a particular aspect, the polymeric binder composition 115 can be comprised of a single polymer or a blend of polymers.

The binder composition can be formed from an epoxy composition, an acrylic composition, a phenolic composition, a polyurethane composition, a urea formaldehyde composition, a polysiloxane composition, or combinations thereof. In addition, the binder composition can include active filler particles, additives, or a combination thereof, as described herein.

The binder composition generally includes a polymer matrix, which binds abrasive particles to the backing or to a compliant coat, if such a compliant coat is present. Typically, the binder composition is formed of cured binder composition. In an embodiment, the binder composition includes a polymer component and a dispersed phase.

The binder composition can include one or more reaction constituents or polymer constituents for the preparation of a polymer. A polymer constituent can include a monomeric molecule, a polymeric molecule, or a combination thereof. The binder composition can further comprise components selected from the group consisting of solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators and agents for influencing the fluidity of the dispersion.

The polymer constituents can form thermoplastics or thermosets. By way of example, the polymer constituents can include monomers and resins for the formation of polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), polymerized alkyd, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, or, in general, reactive resins for the production of thermoset polymers. Another example includes an acrylate or a methacrylate polymer constituent. The precursor polymer constituents are typically curable organic material (i.e., a polymer monomer or material capable of polymerizing or crosslinking upon exposure to heat or other sources of energy, such as electron beam, ultraviolet light, visible light, etc., or with time upon the addition of a chemical catalyst, moisture, or other agent, which cause the polymer to cure or polymerize). A precursor polymer constituent example includes a reactive constituent for the formation of an amino polymer or an aminoplast polymer, such as alkylated urea-formaldehyde polymer, melamine-formaldehyde polymer, and alkylated benzoguanamine-formaldehyde polymer; acrylate polymer including acrylate and methacrylate polymer, alkyl acrylate, acrylated epoxy, acrylated urethane, acrylated polyester, acrylated polyether, vinyl ether, acrylated oil, or acrylated silicone; alkyd polymer such as urethane alkyd polymer; polyester polymer; reactive urethane polymer; phenolic polymer such as resole and novolac polymer; phenolic/latex polymer; epoxy polymer such as bisphenol epoxy polymer; isocyanate; isocyanurate; polysiloxane polymer including alkylalkoxysilane polymer; or reactive vinyl polymer. The binder composition can include a monomer, an oligomer, a polymer, or a combination thereof. In a particular embodiment, the binder composition includes monomers of at least two types of polymers that when cured can crosslink.

In an embodiment, the binder composition can include epoxy constituents and acrylic constituents that when cured form an epoxy/acrylic hybrid polymer. Alternatively, the binder composition can comprise a butyl acrylate polymer. In an embodiment, the binder composition can comprise a cycloaliphatic epoxy resin, a di-acrylate resin, or a combination thereof. In a specific embodiment, the binder composition can comprise a hydrogenated diphenylolpropane (DPP) epoxy resin, an oxetane resin (4-member cyclic ether), a bisphenol A Epoxy Diacrylate resin (diacrylate ester of a bisphenol A epoxy resin), a propoxylated neopentyl glycol diacrylate resin, or combinations thereof.

Size Coat Layer

As described above, layer of polymeric size coat composition 119 (a “size coat”) can be disposed over the polymeric binder composition 115 and abrasive particles 117. The size coat composition 119 can be the same as or different from the polymeric binder composition 115 of the abrasive layer 103 (i.e., the size coat composition can be the same as or different from the make coat composition). The size coat composition can include one or more fillers, additives, or a combination thereof.

In a specific embodiment, the size coat composition 119 can comprise an epoxy resin, an acrylic resin, an acrylate resin, an epoxy acrylate resin, or a combination thereof. In an embodiment, the size coat composition can comprise a reinforcing additive, such as amorphous silica. In a specific embodiment, the size coat composition can comprise a cycloaliphatic epoxy resin, an epoxide, a diepoxide, a butanediol, a triacrylate, a hexaacrylate, a cyclohexylcarboxylate, or a combination thereof. In a specific embodiment, the size coat composition can comprise a silica reinforced cycloaliphatic epoxy resin, an aliphatic epoxidized butanediol, trimethylolpropane triacrylate (TMPTA), dipentaerythritol hexaacrylate (DPHA), (3,4-epoxycyclohexane) methyl 3,4-epoxycyclohexylcarboxylate, or a combination thereof.

In a specific embodiment, the size coat composition can include 5 wt % to 45 wt % of a reinforcing filler, such 10 wt % to 35 wt % of a reinforcing filler.

Supersize Coat Composition

As previously described, the coated abrasive article 100 can optionally comprise a layer of supersize coat composition (not shown) disposed on the size coat composition 119. The supersize coat composition can be the same as or different from the polymeric binder composition 115 of the abrasive layer 103 and can be same as or different than the size coat composition 119 disposed thereon. In another aspect, the supersize coat composition may comprise an anti-loading agent (such as a stearate, such as a metal stearate, such as zinc stearate or calcium stearate) or a grinding aid (such as cryolite, potassium borofluorate), or a combination thereof.

Additives

In a particular aspect, the front coat composition 111, the back coat composition 113, the binder composition 115, the size coat composition 119, or the supersize coat composition (not shown) can include one or more additives. Additives can be available in an amount of 0 wt % to 10 wt % of any polymer layer (i.e., make coat layer, size coat layer, or supersize layer). Suitable additives, for example, can include grinding aids, fibers, lubricants, wetting agents, thixotropic materials, surfactants, thickening agents, pigments, dyes, antistatic agents, coupling agents, plasticizers, suspending agents, pH modifiers, adhesion promoters, lubricants, bactericides, fungicides, flame retardants, degassing agents, anti-dusting agents, dual function materials, initiators, chain transfer agents, stabilizers, dispersants, reaction mediators, colorants, and defoamers. The amounts of these additive materials can be selected to provide the properties desired. These optional additives can be present in any part of the overall system of the coated abrasive product according to embodiments of the present disclosure. Suitable grinding aids can be inorganic based; such as halide salts, for example cryolite, wollastonite, and potassium fluoroborate; or organic based, such as sodium lauryl sulphate, or chlorinated waxes, such as polyvinyl chloride. In an embodiment, the grinding aid can be an environmentally sustainable material.

Embodiments

Embodiment 1. An abrasive belt comprising: an abrasive film having a joint; wherein the abrasive film comprises an abrasive layer disposed on a backing material; wherein the backing material comprises: a backing substrate having a first side and a second side; and a back coat disposed on the second side of the backing substrate; and wherein the joint comprises: a first end of the abrasive film abutting a second end of the abrasive film; a polymeric joint adhesive disposed on the back coat of the first end and the back coat of the second end; and a joint tape disposed over the polymeric joint adhesive.

Embodiment 2. The abrasive belt of embodiment 1, further comprising a Triple Head Test rating of at least 10 minutes, such as at least 15 minutes, at least 20 minutes, or at least 30 minutes.

Embodiment 3. The abrasive belt of embodiment 1, wherein the back coat comprises a layer of a polymeric acrylate composition.

Embodiment 4. The abrasive belt of embodiment 3, wherein the polymeric acrylate composition comprises an ethyl acrylate, an ethylene acrylate, an ethylene-methyl acrylate, an ethylene-ethyl acrylate, or a combination thereof.

Embodiment 5. The abrasive belt of embodiment 4, wherein the layer of polymeric acrylate composition comprises a thickness of at least 0.1 mil to not greater than 3 mil, such as at least 0.25 mil to not greater than 2.5 mil, or at least 0.5 mil to not greater than 2 mil.

Embodiment 6. The abrasive belt of embodiment 1, further comprising a front coat disposed on the first side of the backing substrate between the abrasive layer and the backing substrate.

Embodiment 7. The abrasive belt of embodiment 6, wherein the front coat comprises a layer of a polymeric ethylene composition.

Embodiment 8. The abrasive belt of embodiment 7, wherein the polymeric polyethylene composition comprises a low-density polyethylene, a high-density polyethylene, or a combination thereof.

Embodiment 9. The abrasive belt of embodiment 8, wherein the polymeric polyethylene composition comprises a thickness of at least 0.25 mil to not greater than 5 mil, such as at least 1 mil to not greater than 3 mil, or at least 1.5 mil to not greater than 2.5 mil.

Embodiment 10. The abrasive belt of embodiment 1, wherein the backing substrate comprises a polymeric film.

Embodiment 11. The abrasive belt of embodiment 10, wherein the polymeric film comprises a polyester film.

Embodiment 12. The abrasive belt of embodiment 10, wherein the polymeric film comprises polyethylene terephthalate.

Embodiment 13. The abrasive belt of embodiment 10, wherein the polymeric film comprises a thickness of at least 1 mil to not greater than 10 mil, such as at least 2 mil to not greater than 8 mil, at least 3 mil to not greater than 7 mil, or at least 4 mil to not greater than 6 mil.

Embodiment 14. The abrasive belt of embodiment 10, wherein the polymeric film comprises a surface energy of at least 40 dyne/cm2, such as at least 45 dyne/cm2, as at least 50 dyne/cm2, as at least 55 dyne/cm2.

Embodiment 15. The abrasive belt of embodiment 14, wherein the polymeric film is corona treated.

Embodiment 16. The abrasive belt of embodiment 15, wherein the corona treatment increases the surface energy 5 to 50 dyne/cm2, such as 10 to 35 dyne/cm2.

Embodiment 17. The abrasive belt of embodiment 1, wherein the joint comprises a butt joint.

Embodiment 18. The abrasive belt of embodiment 17, wherein the joint includes a surface energy treatment in a region adjacent the joint.

Embodiment 19. The abrasive belt of embodiment 18, wherein the surface treatment increases the surface energy by 10-30 Dynes/cm2.

Embodiment 20. The abrasive belt of embodiment 18, wherein the surface treatment comprises a corona treatment, a plasma treatment, or a combination thereof.

Embodiment 21. The abrasive belt of embodiment 1, wherein the abrasive layer comprises a polymeric make coat composition and abrasive particles disposed in the make coat composition.

Embodiment 22. The abrasive belt of embodiment 21, wherein the make coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof.

Embodiment 23. The abrasive belt of embodiment 21, wherein the make coat composition further comprises a filler.

Embodiment 24. The abrasive belt of embodiment 21, wherein the abrasive layer further comprises a polymeric size coat composition disposed on the make coat composition and abrasive particles.

Embodiment 25. The abrasive belt of embodiment 21, wherein the size coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof.

Embodiment 26. The abrasive belt of embodiment 21, wherein the make coat composition further comprises a filler.

Embodiment 27. The abrasive belt of embodiment 21, wherein the abrasive particles comprise diamond, cubic boron nitride, or a combination thereof.

Embodiment 28. The abrasive belt of embodiment 21, wherein the abrasive particles comprise a grit size of 10 microns to 500 microns.

EXAMPLES
Example 1.—Sample Coated Abrasive Belt Preparation

A sample coated abrasive film belt was prepared as described herein. In a first step, a backing material was prepared by applying a front coat and a back coat to a backing substrate. Details of the backing material are provided below in Table 1. The completed backing material was stored for later use.