Durable coated abrasive article
View Patent ↗An abrasive article comprising abrasive grains bonded with a binder comprising a matrix polymer and an amphiphilic block copolymer dispersed in the matrix polymer. The abrasive article can be a coated abrasive article, such as an engineered abrasive article, including a backing. The binder can bind the abrasive grains to the backing.
1. An abrasive article comprising abrasive grains bonded with a binder comprising a matrix polymer and an amphiphilic block copolymer dispersed in the matrix polymer,
wherein the matrix polymer is a resin selected from the group consisting of phenolic resin, urea-formaldehyde resin, acrylic resin, epoxy resin, epoxy-acrylate resin, acrylamide resin, silicone resin, isocyanurate resin, melamine-formaldehyde resin, polyimide resin, or any combination thereof,
wherein the amphiphilic block copolymer includes at least a philic block segment miscible with the matrix polymer and at least a phobic block segment immiscible with the matrix polymer, and
wherein the amphiphilic block copolymer includes a block copolymer of polybutylacrylate and polymethylmethacrylate, or block terpolymers thereof, and
wherein the amphiphilic block copolymer forms domains dispersed within the matrix polymer having a diameter not greater than 100 nm.
2. The abrasive article of claim 1 , wherein the binder includes the amphiphilic block copolymer in an amount in a range of 0.5 wt% to 10 wt% based on the weight of the matrix polymer.
3. The abrasive article of claim 1 , wherein the abrasive article exhibits a Stock Removal Performance of at least 1.0 grams.
4. The abrasive article of claim 1 , wherein the abrasive article exhibits an Impact Imprint Index of not greater than 15 mm.
5. The abrasive article of claim 1 , wherein the abrasive article exhibits an Rz Index of not greater than 100 micro-inches.
6. The abrasive article of claim 1 , further comprising a backing wherein the abrasive grains are bonded to the backing by the binder.
7. The coated abrasive article of claim 6 , wherein the binder includes the amphiphilic block copolymer in an amount in a range of 0.5 wt% to 10 wt% based on the weight of the matrix polymer.
8. A method of forming an abrasive article, the method comprising:
dispensing a backing;
coating a slurry on the backing, the slurry comprising abrasive grains and a binder formulation according to claim 1 ; and
curing the matrix polymer precursor.