US 5,178,646 A · Coatable thermally curable binder presursor solutions modified with a reactive diluent, abrasive articles incorporating same, and methods of making said abrasive articles

Abstract

A coatable, thermally curable binder precursor solution, the solution including a 30-95% solids solution of a thermally curable resin and a reactive diluent. The reactive diluent may be selected form urea derivatives, alkylsubstituted 2-aminoalcohols, .beta.-ketoalkylamides, nitro alkanes, and poly(oxyalkylene) compounds, and has at least one functional group independently reactive with methylol groups of the resin and with aldehydes. The thermally curable resin may include up to 50% (wt of total resin) of an ethylenically unsaturated monomer. Method of making abrasive articles are also presented.

Claims127

Dependent claims

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.

10 more elements

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.

10 more elements

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.

10 more elements

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.

10 more elements

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.

10 more elements

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.

9 more elements

(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.

11 more elements

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.

9 more elements

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.

10 more elements

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.

12 more elements

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.

8 more elements

(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.

8 more elements

(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.

8 more elements

(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.

8 more elements

(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.

8 more elements

(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.

6 more elements

(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.

9 more elements

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.

6 more elements

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.

8 more elements

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.

10 more elements

Dependencies are inferred from the claim text.

Facts

Application

07/893,918Filed 4 Jun 1992 · continuation

Priority

22 Jan 1992

Granted

12 Jan 1993

Term ends

Not estimatedThe source records don’t support an estimate.

Classification14 codes

C04B 35/63472
Obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds: condensation polymers of aldehydes or ketones
B24D 3/28
And being essentially organic: resins or natural or synthetic macromolecular compounds
C04B 35/634
Organic additives: polymers
C04B 35/63488
Obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds: polyethers, e.g. alkylphenol polyglycolether, polyethylene…

Abstract

Claims127

Dependent claims

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.

10 more elements

(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.

10 more elements

(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.

10 more elements

(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.

10 more elements

(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.

10 more elements

(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.

9 more elements

(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.

11 more elements

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.

9 more elements

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.

10 more elements

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.

12 more elements

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.

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(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.

8 more elements

(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.

8 more elements

(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.

8 more elements

(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.

8 more elements

(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.

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(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.

9 more elements

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.

6 more elements

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.

8 more elements

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.

10 more elements

Dependencies are inferred from the claim text.

Coatable thermally curable binder presursor solutions modified with a reactive diluent, abrasive articles incorporating same, and methods of making said abrasive articles

Life of this patent

Abstract

Claims127

Coatable thermally curable binder presursor solutions modified with a reactive diluent, abrasive articles incorporating same, and methods of making said abrasive articles

Life of this patent

Abstract

Claims127