Aqueous Resin Composition for Abrasive Articles and Resulting Articles

Abstract

An aqueous polymer binder composition adapted for the manufacture of abrasive articles, such as coated abrasive articles, comprising at least one saccharide, at least one polycarboxylic organic acid, and at least one crosslinking catalyst. The aqueous composition is formaldehyde-free and can further comprise rheology modifiers, fillers, and hydrophobizing agents.

1 . A coated abrasive article comprising:
 a backing; and   an abrasive layer overlying the backing;   wherein the abrasive layer comprises
 abrasive particles and 
 a polymer binder composition including
 at least one saccharide, 
 at least one polycarboxylic organic acid, and 
 at least one crosslinking catalyst. 
 
   
     
     
         2 . A coated abrasive article comprising:
 a backing; and   an abrasive layer overlying the backing; and   a size coat comprising
 a polymer binder composition including
 at least one saccharide, 
 at least one polycarboxylic organic acid, and 
 at least one crosslinking catalyst. 
 
   
     
     
         3 . A coated abrasive article according to  claim 1  wherein the saccharide is corn syrup, dextrin, or a combination thereof. 
     
     
         4 . A coated abrasive article according to  claim 1  wherein the polymer binder further comprises at least one member selected from the group consisting of rheology modifiers and hydrophobic additives. 
     
     
         5 . (canceled) 
     
     
         6 . A coated abrasive article according to  claim 1 , wherein the saccharide is a monosaccharide, a polysaccharide, or a combination thereof. 
     
     
         7 . (canceled) 
     
     
         8 . A coated abrasive article according to  claim 1 , wherein the saccharide comprises is glucose, mannose or galactose. 
     
     
         9 . A coated abrasive article according to  claim 6 , wherein the polysaccharide has a number-average molecular weight of less than 5000. 
     
     
         10 . A coated abrasive article according to  claim 9 , wherein the polysaccharide has a polydispersity index (IP), defined by the ratio of the weight-average molecular weight to the number-average molecular weight, which is less than or equal to 12. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . A coated abrasive article according to  claim 1 , further comprising a monomeric polycarboxylic organic acid. 
     
     
         14 . A coated abrasive article according to  claim 13 , wherein the monomeric polycarboxylic acid is citric acid. 
     
     
         15 . A coated abrasive article according to  claim 1 , wherein the polymeric polycarboxylic organic acid is chosen from homopolymers of an unsaturated carboxylic organic acid and unsaturated dicarboxylic acid monoesters, and copolymers of at least one aforementioned unsaturated carboxylic acid and of at least one vinyl monomer. 
     
     
         16 . A coated abrasive article according to  claim 1 , wherein the polymeric polycarboxylic organic acid contains at least one polymer or one copolymer of (meth)acrylic acid. 
     
     
         17 . A coated abrasive article according to  claim 1 , wherein the amount, by weight, of saccharide represents 10% to 90% of the total weight of the saccharide and polycarboxylic organic acid. 
     
     
         18 . A coated abrasive article according to  claim 1 , wherein the crosslinking catalyst is chosen from compound salts that contain phosphorus, Lewis acids and bases, organic amines, metal oxides, metal sulphates, metal chlorides, urea sulphates, urea chlorides and silicate-based catalysts and compounds that contain fluorine and boron. 
     
     
         19 . A coated abrasive article according to  claim 18 , wherein the crosslinking catalyst is sodium hypophosphite, sodium phosphite, or a combination thereof. 
     
     
         20 . A coated abrasive article according to one  claim 1 , wherein the amount of crosslinking catalyst represents 1% to 15% of the total weight of the saccharide and polycarboxylic organic acid. 
     
     
         21 . A coated abrasive article according to  claim 1 , wherein the solids content, calculated on the basis of all of the organic constituents, varies from 30% to 75%.