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US 5,306,319 AGranted
Surface treating articles and methods of making same
AssigneeMinnesota Mining and Manufacturing Company
InventorsSubramanian Krishnan, Eugene J. Miller, Mary B. Donovan, Ramona M. Janochoski, Caroline Couvelard
Life of this patent
Estimating the term…
Abstract
Surface treating articles having varying degree of smear-resistance and their methods of manufacture are presented. One preferred article is characterized by an organic matrix substantially engulfed by a novel, tough, adherent elastomeric resinous binder system comprising the reaction product of either (1) a polyurethane prepolymer, or (2) a polyurethane polymer emulsion with an epoxy-functional material and an amine-functional material in an aqueous system.
Claims64
A surface treating article comprising an organic matrix substantially engulfed by a binder, the binder comprising materials selected from the group consisting of:
- a) the reaction product of a plurality of linear isocyanate-terminated polyurethane prepolymers with a first adduct, said first adduct comprising the reaction product of an amine-functional material having an average amine functionality of at least 2 and an epoxy-functional material having an average epoxy functionality of at least 2, with the provisos that said first adduct has at least one amine reactive with said isocyanates and at least one secondary hydroxyl moiety reactive with said isocyanates;
- and
- b) the reaction product of a plurality of linear polyurethane polymers having a high molecular weight, said polymers having a plurality of ionic moieties, with a second adduct, the second adduct selected from the group consisting of
- i) the reaction product of the amine-functional material and the epoxy-functional material of part a), and
- ii) the reaction product of the amine-functional material and a homopolymerized epoxy-functional material,
- with the provisos that the second adduct has at least one epoxy functional group reactive with the ionic moieties.
3 more elements
A surface treating article comprising an open, lofty, three-dimensional nonwoven web comprised of a plurality of organic polymeric fibers, at least a portion of said fibers bound together at points where they contact by a first binder, the first binder comprising materials selected from the group consisting of:
- a) the reaction product of a plurality of linear isocyanate-terminated polyurethane prepolymers with a first adduct, said first adduct comprising the reaction product of an amine-functional material having an average amine functionality of at least 2 and an epoxy-functional material having an average epoxy functionality of at least 2, with the provisos that said first adduct has at least one amine reactive with said isocyanates and at least one secondary hydroxyl moiety reactive with said isocyanates;
- and
- b) the reaction product of a plurality of linear polyurethane polymers having a high molecular weight, said polymers having a plurality of ionic moieties, with a second adduct, the second adduct selected from the group consisting of
- i) the reaction product of the amine-functional material and an epoxy-functional material of part a) above, and
- ii) the reaction product of the amine-functional material and a homopolymerized epoxy-functional material,
- with the provisos that the second adduct has at least one epoxy functional group reactive with the ionic moieties.
3 more elements
A method of making a layered composite from which a surface treating article may be machined, the method comprising:
- a) forming an open, lofty, three-dimensional nonwoven web comprised of organic fibers;
- b) coating a major portion of the fibers of the nonwoven web with a prebond precursor composition to form a first coated web;
- c) exposing the first coated web to energy sufficient to at least partially cure the prebond precursor composition to form an open, lofty, three-dimensional nonwoven prebonded web of said fibers;
- d) coating at least a portion of the fibers of the prebonded web with an aqueous slurry comprising water, abrasive particles and a binder to form a second coated web, the binder comprising materials selected from the group consisting of:
- i) the reaction product of a plurality of linear isocyanate-terminated polyurethane prepolymers with a first adduct, said first adduct comprising the reaction product of an amine-functional material having an average amine functionality of at least 2 and an epoxy-functional material having an average epoxy functionality of at least 2, with the provisos that said first adduct has at least one amine reactive with said isocyanates and at least one secondary hydroxyl moiety reactive with said isocyanates;
- and
- ii) the reaction product of a plurality of linear polyurethane polymers having a high molecular weight, said polymers having a plurality of ionic moieties, with a second adduct, the second adduct selected from the group consisting of
- a) the reaction product of the amine-functional material and an epoxy-functional material of part a) above, and
- b) the reaction product of the amine-functional material and a homopolymerized epoxy-functional material,
- with the provisos that the second adduct has at least one epoxy functional group reactive with the ionic moieties;
- e) exposing the second coated web to energy sufficient to remove substantially all of the water, thereby forming a substantially dried web;
- f) juxtaposing a plurality of said substantially dried webs to form a precursor layered composite;
- and
- g) compressing the precursor layered composite with pressure and at a temperature sufficient to form the layered composite.
11 more elements
A method of making a layered composite from which a surface treating article may be machined, said method comprising:
- a) forming an open, lofty, three-dimensional nonwoven web comprised substantially of hydrophilic organic fibers;
- b) coating a major portion of the fibers of the nonwoven web employing an effective pressure with an aqueous composition comprising water and a binder to form a coated web, the binder comprising materials selected from the group consisting of:
- i) the reaction product of a plurality of linear isocyanate-terminated polyurethane prepolymers with a first adduct, said first adduct comprising the reaction product of an amine-functional material having an average amine functionality of at least 2 and an epoxy-functional material having an average epoxy functionality of at least 2, with the provisos that said first adduct has at least one amine reactive with said isocyanates and at least one secondary hydroxyl moiety reactive with said isocyanates;
- and
- ii) the reaction product of a plurality of linear polyurethane polymers having a high molecular weight, said polymers having a plurality of ionic moieties, with a second adduct, the second adduct selected from the group consisting of
- a) the reaction product of the amine-functional material and an epoxy-functional material of part a) above, and
- b) the reaction product of the amine-functional material and a homopolymerized epoxy-functional material,
- with the provisos that the second adduct has at least one epoxy functional group reactive with the ionic moieties;
- c) juxtaposing a plurality of said coated webs to form a precursor layered composite;
- and
- d) compressing the precursor layered composite with pressure and at a temperature sufficient to form the layered composite.
8 more elements
A method of making a nonwoven surface treating article, the method-comprising:
- a) forming an open, lofty, three-dimensional nonwoven web of organic fibers;
- b) entangling the organic fibers of the nonwoven web to form an entangled web having an effective density;
- c) coating the entangled web with an aqueous composition comprising water and a binder to form a first coated web, the binder comprising materials selected from the group consisting of:
- i) the reaction product of a plurality of linear isocyanate-terminated polyurethane prepolymers with a first adduct, said first adduct comprising the reaction product of an amine-functional material having an average amine functionality of at least 2 and an epoxy-functional material having an average epoxy functionality of at least 2, with the provisos that said first adduct has at least one amine reactive with said isocyanates and at least one secondary hydroxyl moiety reactive with said isocyanates;
- and
- ii) the reaction product of a plurality of linear polyurethane polymers having a high molecular weight, said polymers having a plurality of ionic moieties, with a second adduct, the second adduct selected from the group consisting of
- a) the reaction product of the amine-functional material and an epoxy-functional material of part a) above, and
- b) the reaction product of the amine-functional material and a homopolymerized epoxy-functional material,
- with the provisos that the second adduct has at least one epoxy functional group reactive with the ionic moieties;
- d) exposing the first coated web to energy sufficient to substantially remove the water, thus forming a dried, coated, entangled web;
- e) coating the dried, coated, entangled web with a slurry comprising abrasive particles and a binder precursor to form a slurry coated web;
- and
- f) exposing the slurry coated web to energy sufficient to substantially cure the binder precursor, thus forming a nonwoven surface treating article.
10 more elements
An aqueous coatable composition comprising materials selected from the group consisting of:
- a) the reaction product of a plurality of linear isocyanate-terminated polyurethane prepolymers with a first adduct, said first adduct comprising the reaction product of an amine-functional material having an average amine functionality of at least 2 and an epoxy-functional material having an average epoxy functionality of at least 2, with the provisos that said first adduct has at least one amine reactive with said isocyanates and at least one secondary hydroxyl moiety reactive with said isocyanates;
- and
- b) the reaction product of a plurality of linear polyurethane polymers having a high molecular weight, said polymers having a plurality of ionic moieties, with a second adduct, the second adduct selected from the group consisting of
- i) the reaction product of the amine-functional material and the epoxy-functional material of part a), and
- ii) the reaction product of the amine-functional material and a homopolymerized epoxy-functional material,
- with the provisos that the second adduct has at least one epoxy functional group reactive with the ionic moieties.
3 more elements
Dependencies are inferred from the claim text.