Abrasive article and a process for preparation thereof

Abstract

The present invention relates to abrasive articles, more specifically to coated abrasive article with non-woven backing and a method of their preparation.

1 . An abrasive article comprising:
 a) a non-woven backing; and   b) one or more layers of abrasive slurry deposited over the backing,   
       wherein said non-woven backing is impregnated with an acrylic emulsion and wherein the abrasive slurry comprises of one or more mineral particles and binder. 
     
     
         2 . The article as claimed in  claim 1 , wherein the non-woven backing is selected from a group consisting of polymer materials. 
     
     
         3 . The article as claimed in  claim 2 , wherein the polymer material is spun-bonded polypropylene fabric. 
     
     
         4 . The article as claimed in  claim 1 , comprising more than one layer of abrasive slurry deposited over the backing. 
     
     
         5 . The article as claimed in  claim 4 , wherein the mineral particles are coarser in outermost layer of abrasive slurry and gradually decreases to finer particles in layers of abrasive slurry towards backing. 
     
     
         6 . The article as claimed in  claim 1 , wherein the mineral particles are selected from a group consisting of silicon carbide, aluminium oxides, chromia, alumina zirconia, diamond, iron oxide, ceria, cubic boron nitride, boron carbide, garnet and combinations thereof 
     
     
         7 . The article as claimed in  claim 1 , wherein the binder comprises of a resin, filler and/or a curing agent. 
     
     
         8 . The article as claimed in  claim 7 , wherein the resin is selected from a group consisting of thermal curable phenolics, oil modified alkyds, thermal curable epoxies or UV-curable epoxy-acrylate. 
     
     
         9 . The article as claimed in  claim 7 , wherein the filler is selected from a group consisting of clay, silica, talc, calcium carbonate or mixtures thereof. 
     
     
         10 . The article as claimed in  claim 7 , wherein the curing agent is selected from a group consisting of thermal curing agents, UV curing agents or combinations thereof. 
     
     
         11 . A backing for abrasive article comprising non-woven spun-bonded polypropylene fabric impregnated with acrylic emulsion 
     
     
         12 . The backing as claimed in  claim 11 , wherein the acrylic emulsion is selected from a group consisting of SBR latex, Nitrile latex, vinyl latex, acrylated urethanes, acrylated acrylics, acrylated epoxies, aminoplast derivatives having pendant alpha, beta unsaturated carbonyl groups, isocyanurate derivatives having at least one pendant acrylate group, isocyanate derivatives having at least one pendant acrylate group, acrylated polyesters, and mixtures thereof. 
     
     
         13 . The backing as claimed in  claim 11 , wherein the acrylic emulsion optionally comprises of at least one filler. 
     
     
         14 . A process for preparing the backing as claimed in  claim 11  comprising:
 a) providing a non-woven spun-bonded polypropylene fabric; 
 b) surface treating or priming the fabric; and 
 c) impregnating the fabric with an acrylic emulsion. 
 
     
     
         15 . A coated abrasive article comprising the backing as claimed in  claim 11  and one or more layers of abrasive slurry deposited over the backing. 
     
     
         16 . The article as claimed in  claim 1 , in the form of a sheet, disc or a roll, resistant to curling and piercing. 
     
     
         17 . A process of preparing an abrasive article comprising the steps of:
 a) depositing abrasive slurry comprising one or more mineral particles and binder over a backing as a layer;   b) heating the abrasive slurry deposited over the backing; and   c) curing the abrasive slurry deposited over the backing;   d) optionally   e) repeating steps (a) to (c) to obtain one or more layers of abrasive slurry over backing;   f) coating the cured abrasive slurry with a stearate formulation.   
     
     
         18 . The process as claimed in  claim 17 , wherein said backing is selected from a group consisting of non-woven materials. 
     
     
         19 . The process as claimed in  claim 17  wherein said backing is impregnated with an acrylic emulsion. 
     
     
         20 . The process as claimed in  claim 17 , wherein said non-woven material is spun-bonded polypropylene fabric. 
     
     
         21 . The process as claimed in  claim 19 , wherein the backing is primed or surface treated prior to impregnation with acrylic emulsion. 
     
     
         22 . The process as claimed in  claim 17 , wherein the deposition of abrasive slurry over the backing is carried out by techniques selected from roll coating, spray coating, screen printing, roto gravure printing, knife coating or a combination thereof. 
     
     
         23 . The process as claimed in  claim 17 , wherein the heating is performed at a temperature in range of 50° C. to 150° C. 
     
     
         24 . The process as claimed in  claim 17 , wherein the curing is performed by thermal curing or UV curing, or a combination thereof. 
     
     
         25 . The process as claimed in  claim 17 , wherein the stearate formulation comprises calcium stearate and/or zinc stearate.