Non-abrasive abrasive composites

Abstract

The present invention provides an abrasive composite that, when polymerized, has a glass transition temperature (T g ) and a first crosslinkable binder component having a modulus of elasticity of less than about 150 MPa; T above room temperature g a second crosslinkable binder component having a material capable of initiating addition polymerization; and particulate particles having a Mohs hardness value of about 3 or less.

Description

[Background technology]

[0001] The desire to protect sensitive and expensive surfaces from hard minerals and resins has led to increased consumer interest in non-abrasive scrubbing / cleaning products for use in household cleaning. In addition, it is also desirable that the cleaning product itself not become soiled during the cleaning process. That is, it is desirable that the cleaning product either resist the accumulation of soil on its surface or be able to wash away soil after use.

[0002] A simplified theory of abrasive performance assumes that the workpiece material removal rate is related to the mechanical properties (i.e., hardness), size, and shape (i.e., sharpness) of the abrasive material. Meanwhile, the likelihood of an abrasive material generating scratches on a workpiece is generally discussed in terms of the relative hardness of the abrasive material and the workpiece. While size and shape certainly affect whether an abrasive material will scratch and how noticeable the scratches will be, actually forming scratches requires deformation of the workpiece by the abrasive material. For this to occur, the abrasive material must be harder than the workpiece. Thus, assuming the abrasive material is not hard enough to deform the workpiece, dirt located on the surface of a workpiece that has a lower hardness than the workpiece itself can be effectively cleaned with an abrasive material having a size and shape appropriate for high dirt removal rates, i.e., relatively tall protrusions with relatively sharp edges, e.g., square pyramidal abrasive protrusions having a height of approximately 500 microns and a base width of 500 to 1200 microns, with the formed edges generally having a radius of curvature of less than 50 microns. [Brief explanation of the drawings]

[0003] The present disclosure may be more fully understood from the following detailed description of various embodiments of the disclosure, when considered in conjunction with the accompanying drawings. [Figure 1] 1 shows a perspective view of a first embodiment of a cleaning article of the present invention. [Figure 2] 1 shows a perspective view of a second embodiment of a cleaning article of the present invention. [Figure 3]1 shows a perspective view of a third embodiment of a cleaning article of the present invention.

[0004] While the above-identified Figures set forth several embodiments of the present disclosure, other embodiments are also contemplated as noted herein. In all cases, this disclosure presents the invention by way of representation and not limitation. It is to be understood that numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of the present invention. Summary of the Invention

[0005] In one embodiment, the present invention provides a polymerizable composition that, when polymerized, has a glass transition temperature (T g ) and a first crosslinkable binder component having a modulus of elasticity of less than about 150 MPa, and a T above room temperature. g a component capable of initiating addition polymerization; and particulate particles having a Mohs hardness value of about 3 or less.

[0006] In another embodiment, the invention is a structured abrasive article comprising a substrate and abrasive composites adhered to the substrate. The abrasive composites, when polymerized, have a glass transition temperature (T) below room temperature. g ) and a first crosslinkable binder component having a modulus of elasticity of less than about 150 MPa, and a T above room temperature. g a component capable of initiating addition polymerization; and finely divided particles having a Mohs hardness value of about 3 or less. DETAILED DESCRIPTION OF THE INVENTION

[0007] The present invention provides abrasive composites that can be used for cleaning or scrubbing, which are substantially non-abrasive and can substantially wash away dirt that accumulates on the surface of the abrasive composite during use. The abrasive composites are designed to have high scrubbing performance without causing any visible damage to the underlying substrate being cleaned. In one embodiment, the abrasive composites can be used for household cleaning with substantially no or minimal damage to materials such as poly(tetrafluoroethylene), stainless steel, and hard plastics. After being used for cleaning, the abrasive composites can essentially wash away any debris removed from the surface being cleaned. In addition, the abrasive composites of the present invention are durable and long-lasting.

[0008] The abrasive composites of the present invention are formed by dispersing an inorganic or fine particle phase in an organic binder phase. In the abrasive composites, relatively fine particles are bound together by a binder, which functions as a dispersion medium for the fine particles and, if desired, provides a means for adhering the abrasive composite to a substrate or backing. These fine particles act primarily as fillers and viscosity modifiers in the uncured liquid precursor, in contrast to conventional coated or nonwoven abrasives, in which the fine particles generally have high Mohs hardness values ​​and can remove significant material from the workpiece by gouging in a manner that depends on the grain shape, hardness, and size of the particles and the pressure and shape of the abrasive operation. In this application, such gouging constitutes "scratches," and while individual fine particles with low Mohs hardness values ​​may not cause visible scratches on the test surface, minerals can affect scratch formation by modifying the mechanical properties of the composite according to the composite's general mixing rules. In one embodiment, the abrasive composites of the present invention contain fine particles with a Mohs hardness of about 3 or less. In one embodiment, the fine particle phase has a d of less than about 50 microns, particularly less than about 30 microns. 90 and inorganic minerals having a Mohs hardness value of about 3 or less. Increasing the particle size distribution increases the probability of mar formation and reduces control over the rheological properties of the liquid slurry before hardening.

[0009] Examples of particulate particles having a Mohs hardness of less than 3 include, but are not limited to, clays (e.g., kaolinite, montmorillonite, illite, chlorite clays, talc, soapstone), gypsum, calcium carbonate (e.g., limestone and marble), mica, rock salt, and jet. Furthermore, many soft organic materials can provide the same functions as soft particulate mineral particles, such as crushed or ground nut / fruit shells, including but not limited to almond, argan, coconut, hazelnut, macadamia, pecan, pine, pistachio, and walnut; crushed or ground fruit endocarp / pits, including but not limited to apricot, olive, peach, cherry, plum, palm, and siamese; crushed or ground corn cobs; ground or ground arthropod shells; wood flour; crushed or ground synthetic polymeric materials, including but not limited to any thermoplastic polymer or any thermosetting polymer; and unmodified naturally occurring polymeric materials, including but not limited to polyhydroxyalkanoates; precision-molded synthetic polymeric materials, etc. In one embodiment, the abrasive composite comprises two or more types of particulate particles.

[0010] In one embodiment, the abrasive composite comprises from about 26% to about 80% by weight, specifically from about 47% to about 65% by weight, and more specifically from about 52% to about 61% by weight of the fine particle.

[0011] The binder of the abrasive composite is capable of providing a medium in which the particulate particles can be dispersed. The binder generally comprises a soft crosslinkable binder component, a hard crosslinkable binder component, and a material capable of initiating addition polymerization. The soft crosslinkable binder component, when polymerized, has a glass transition temperature (T) below room temperature. g) (thereby being rubbery and deformable) and has a modulus of elasticity of less than about 150 MPa. In one embodiment, the soft crosslinkable binder component includes a urethane diacrylate or triacrylate. Examples of suitable soft crosslinkable binder components include, but are not limited to, aliphatic urethane diacrylates. In one embodiment, the soft crosslinkable binder component, when polymerized, has an elongation at break of greater than about 25%.

[0012] The hard crosslinkable binder component is heated to a temperature above room temperature, T g (thereby being glassy and rigid). In one embodiment, the hard crosslinkable binder component comprises a difunctional or trifunctional acrylate. Examples of suitable hard crosslinkable binder components include, but are not limited to, trimethylolpropane triacrylate.

[0013] In one embodiment, the material capable of initiating addition polymerization is a UV photoinitiator.

[0014] Empirically, no single binder material screened produced the desired combination of high cleaning performance and low surface mar resistance. Cleaning performance is benefited by a higher modulus, to the detriment of surface mar avoidance, while a lower modulus benefits surface mar avoidance, to the detriment of cleaning performance. By using a miscible blend of soft and hard binder components, the glass transition and stiffness of the binder mixture can be tailored to optimize the balance between cleaning performance and surface mar, avoiding the more costly molecular engineering required to synthesize a single material with the desired glass transition temperature and modulus.

[0015] In one embodiment, the binder can harden or gel relatively quickly, allowing for rapid production of abrasive composites. Some binders gel relatively quickly but require a longer time to fully cure. The gelling preserves the shape of the composite until hardening begins. A fast-hardening or fast-gelling binder can result in a coated abrasive article with a high consistency abrasive composite. Examples of binders suitable for the present invention include, but are not limited to, thermoplastic resins, phenolic resins, aminoplast resins, urethane resins, epoxy resins, acrylate resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, hot melt glues, and mixtures thereof.

[0016] Depending on the binder used, curing or gelling can be achieved by an energy source known to those skilled in the art. For example, the energy source may include, but is not limited to, heat, infrared radiation, electron beam, ultraviolet radiation, or visible light radiation. A radiation-curable binder is any binder that can be at least partially cured or at least partially polymerized by radiation energy. Typically, these binders polymerize via a free radical mechanism.

[0017] When the binder is cured by ultraviolet radiation, a photoinitiator is required to initiate free radical polymerization. Examples of photoinitiators include, but are not limited to, organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acrylic halides, hydrazones, mercapto compounds, pyrylium compounds, triacrylimidazoles, bisimidazoles, chloroalkyltriazines, benzil ketals, thioxanthones, and acetophenone derivatives. Other examples include benzoin and its derivatives, such as α-methylbenzoin, α-phenylbenzoin, α-allylbenzoin, α-benzylbenzoin, benzoin ethers, such as benzil dimethyl ketal (e.g., commercially available as IRGACURE 651 from Ciba Specialty Chemicals, Tarrytown, NY), benzoin methyl ether, benzoin ethyl ether, benzoin n-butyl ether, acetophenone and its derivatives, such as 2-hydroxy-2-methyl-1-phenyl-1-propanone (e.g., DAROCUR 1173 from Ciba Specialty Chemicals), and 1-hydroxycyclohexyl phenyl ketone (e.g., IRGACURE 184 from Ciba Specialty Chemicals), 2-methyl-1-[4-(methylthio)phenyl]-2-(4-morpholinyl)-1-propanone (e.g., IRGACURE 185 from Ciba Specialty Chemicals), and 1-hydroxycyclohexyl phenyl ketone (e.g., IRGACURE 186 from Ciba Specialty Chemicals). 907, 2-benzyl-2-(dimethylamino)-1-[4-(4-morpholinyl)phenyl]-1-butanone (e.g., IRGACURE 369 from Ciba Specialty Chemicals). Other examples include phosphorus-containing organic molecules such as bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide (e.g., IRGACURE 819 from Ciba Specialty Chemicals) and ethyl (2,4,6-trimethylbenzoyl)phenylphosphinate (e.g., TPO-L from Ciba Specialty Chemicals).Even more useful photoinitiators include, for example, pivaloin ethyl ether, anisoin ethyl ether, anthraquinones (e.g., anthraquinone, 2-ethylanthraquinone, 1-chloroanthraquinone, 1,4-dimethylanthraquinone, 1-methoxyanthraquinone, or benzanthraquinone), halomethyltriazines, benzophenone and its derivatives, iodonium and sulfonium salts, titanium complexes such as bis(e-5-2,4-cyclopentadien-1-yl)-bis[2,6-difluoro-3-(1H-pyrrol-1-yl)phenyl]titanium (e.g., CGI784DC from Ciba Specialty Chemicals), and halonitrobenzenes (e.g., 4-bromomethylnitrobenzene), mono- and bisacylphosphines (e.g., IRGACURE 1700, IRGACURE 1800, IRGACURE 1850, and DAROCUR 4265 from Ciba Specialty Chemicals). In one embodiment, more than one photoinitiator is used, for example, one or more spectral sensitizers (e.g., dyes) may be used in conjunction with a photoinitiator to increase the sensitivity of the photoinitiator to a particular source of actinic radiation.

[0018] In one embodiment, the abrasive composite comprises from about 15% to about 35% by weight, specifically from about 22% to about 28% by weight, and more specifically from about 24% to about 27% by weight of the soft crosslinkable binder component. In one embodiment, the abrasive composite comprises from about 8% to about 28% by weight, specifically from about 10% to about 15% by weight, and more specifically from about 11% to about 14% by weight of the hard crosslinkable binder component. In one embodiment, the abrasive composite comprises from about 0.5% to about 5% by weight, specifically from about 0.6% to about 1% by weight, and more specifically from about 0.7% to about 0.9% by weight of a material capable of initiating addition polymerization.

[0019] The binder may be radiation-curable through an addition polymerization mechanism. A silane coupling agent may be included in the slurry of the particulate particles and binder precursor to promote crosslinking association between the binder and the particulate particles. In one embodiment, the silane coupling agent may be present in an amount of about 0% to about 1% by weight, specifically about 0.05% to about 0.4% by weight, and more specifically about 0.1% to about 0.3% by weight. However, those skilled in the art will understand that other amounts may be used, depending, for example, on the size of the mineral. Suitable silane coupling agents include, for example, methacryloxypropyl silane, vinyltriethoxysilane, vinyltris(2-methoxyethoxy)silane, 3,4-epoxycyclohexylmethyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, and gamma-mercaptopropyltrimethoxysilane (e.g., available from Witco Corp. of Greenwich, Conn. under the trade names A-174, A-151, A-172, A-186, A-187, and A-189, respectively), allyltriethoxysilane, diallyldichlorosilane, divinyldiethoxysilane, meta-parastyrylethyltrimethoxysilane (e.g., available from United Chemical and S1588, respectively, from Silicone Industries, Bristol, Pa.), dimethyldiethoxysilane, dihydroxydiphenylsilane, triethoxysilane, trimethoxysilane, triethoxysilanol, 3-(2-aminoethylamino)propyltrimethoxysilane, methyltrimethoxysilane, vinyltriacetoxysilane, methyltriethoxysilane, tetraethylorthosilicate, tetramethylorthosilicate, ethyltriethoxysilane, amyltriethoxysilane, ethyltrichlorosilane, amyltrichlorosilane, phenyltrichlorosilane, phenyltriethoxysilane, methyltrichlorosilane, methyldichlorosilane, dimethyldichlorosilane, dimethyldiethoxysilane, and mixtures thereof.

[0020] Other materials can be added to the abrasive composites for special purposes, including, but not limited to, monofunctional acrylic monomers, thermal free radical initiators, accelerators, polymer waxes or beads, leveling agents, wetting agents, matting agents, colorants, dyes, pigments, lubricants, adhesion promoters, fillers, rheology modifiers, thixotropic agents, plasticizers, UV absorbers, UV stabilizers, dispersants, antioxidants, antistatic agents, lubricants, opacifying agents, defoamers, antibacterial agents, fungicides, and combinations thereof. In one embodiment, the additives are organic. In one embodiment, the abrasive composites contain up to about 1 wt. % of a dispersant, specifically about 0.1 wt. % to about 0.8 wt. %, more specifically about 0.2 wt. % to about 0.6 wt. %. In one embodiment, the abrasive composites contain up to about 1 wt. % of a coupling agent, specifically about 0.05 wt. % to about 0.4 wt. %, more specifically about 0.1 wt. % to about 0.3 wt. %. In one embodiment, the abrasive composites comprise up to about 1 wt. %, specifically up to about 0.3 wt. %, and more specifically up to about 0.2 wt. % colorant. In one embodiment, the abrasive composite comprises about 15% to about 35% by weight, specifically about 22% to about 28% by weight, more specifically about 26.8% by weight of a soft crosslinkable binder component; about 8% to about 28% by weight, specifically about 22% to about 15% by weight, more specifically about 12.6% by weight of a hard crosslinkable binder component; about 0.5% to about 5% by weight, specifically about 0.6% to about 1% by weight, more specifically about 0.8% by weight of a photoinitiator; about 25% to about 55% by weight, specifically about 35% to about 45% by weight, more specifically about 42.1% by weight of first particulate particles; and about 1% to about 25% by weight, specifically about 12% to about 20% by weight, more specifically about 16.9% by weight of second particulate particles.

[0021] Although the abrasive composites contain a binder phase and a mineral phase, the mineral phase does not contribute to the scrubbing ability of the abrasive composites and functions more as a filler. Rather, the scrubbing performance results from the properties of the binder phase and the mineral phase as a whole.

[0022] In one embodiment, the abrasive composites are used to form structured abrasive articles comprising a plurality of precision-shaped abrasive composites attached to a substrate. As used herein, "precision-shaped abrasive composite" refers to a shaped abrasive composite formed by curing one or more binder components of a flowable mixture that also contains soft mineral particles, while the mixture is supported on a backing and fills a cavity on the surface of a manufacturing tool. Such precision-shaped abrasive composites have the exact same shape as the cavity. In one embodiment, the abrasive composites may be pyramidal, and their dimensions are substantially precise.

[0023] To form a structured abrasive article, a plurality of precision-shaped abrasive composites are attached to at least one major surface of a substrate. The precision-shaped abrasive composites provide three-dimensional shapes that protrude outward from the surface of the substrate. The abrasive composites can be arranged on the substrate in either a pattern (i.e., a non-random arrangement) or a random arrangement. In one embodiment, the abrasive composites are arranged on the substrate in a non-random arrangement that exhibits some degree of repetition.

[0024] Suitable materials for the substrate of the present invention include, but are not limited to, polymeric films, paper, cloth, metal films, vulcanized fibers, nonwoven substrates, combinations thereof, and chemically treated versions thereof. In one embodiment, the substrate is a polymeric film such as a polyester or polyurethane film. In one embodiment, the substrate is transparent to ultraviolet radiation. In one embodiment, the substrate is coated with an adhesion-promoting layer such as poly(ethylene-co-acrylic acid) or a UV-curable "tie coat" layer, or undergoes an adhesion-promoting surface modification such as corona or flame treatment or electron beam irradiation. The substrate can be laminated to another substrate after the coated abrasive article is formed. For example, the substrate can be laminated to a flexible or rigid polyurethane foam material, providing a means for the user to effectively manipulate the abrasive.

[0025] The manufacturing tool can be used to form abrasive articles with precision-shaped abrasive coatings or to produce precision-shaped abrasive composites. The manufacturing tool has a surface defining a major plane, which includes a plurality of cavities extending from the major plane as recesses. These cavities define the inverse shape of the abrasive composites and serve to generate the shape, size, and arrangement of the abrasive composites. The cavities can be provided in essentially any geometric shape that is the inverse of a suitable geometric shape for the abrasive composites or abrasive composite particles. For example, the abrasive composites may be cubic, cylindrical, prismatic, hemispherical, rectangular, pyramidal, truncated pyramidal, conical, truncated conical, and flat-topped pillar-like. The dimensions of the cavities are selected to achieve the desired areal density of the abrasive composites. In one embodiment, the cavities can be present in a dot-like pattern, with adjacent cavities abutting each other. In one embodiment, the shape of the cavities is selected so that the surface area of ​​the abrasive composites decreases as they move away from the backing.

[0026] The production tool can take the form of a belt, a sheet, a continuous sheet or web, a coating roll such as a rotogravure roll, a sleeve mounted on a coating roll, or a die. In one embodiment, the production tool is replicated from a master tool. The master tool can be manufactured by any conventional technique known to those skilled in the art, including, but not limited to, photolithography, knurling, engraving, hobbing, electroforming, and diamond turning. U.S. Pat. No. 5,851,247 (Stoetzel et al.) describes a production tool made of a thermoplastic material that can be replicated from a master tool, and is incorporated herein by reference. When a production tool is replicated from a master tool, the master tool is provided with the inverse of the pattern desired for the production tool. In one embodiment, the master tool is made from a nickel-plated metal, such as nickel-plated aluminum, nickel-plated copper, or nickel-plated bronze. A production tool can be replicated from a master tool by pressing a sheet of thermoplastic material against the master tool while heating the master tool and / or the thermoplastic sheet, such that the thermoplastic material is embossed with the master tool pattern. Alternatively, the thermoplastic material can be extruded or cast directly onto the master tool. The thermoplastic material is then cooled to a solid state and separated from the master tool to produce the production tool. The production tool may optionally contain a release coating to allow easier release of the abrasive article. Examples of suitable release coatings include, but are not limited to, silicones and fluorochemicals. Preferred methods for producing production tools are disclosed in U.S. Pat. No. 5,435,816 (Spurgeon et al.), U.S. Pat. No. 5,658,184 (Hoopman et al.), and U.S. Patent Application No. 08-923,862, filed September 3, 1997, entitled "Method and Apparatus for Knurling a Workpiece, Method of Molding an Article with Such Workpiece, and Such Molded Article" (Hoopman), the disclosures of which are incorporated herein by reference.

[0027] The rheology of the abrasive composite before curing is important for its ability to be coated with high fidelity into the cavity of a manufacturing tool when used to form an abrasive article.In one embodiment, a structured abrasive article can be made by first introducing a flowable and hardenable slurry containing a mixture of a binder precursor and multiple minerals into the cavity contained on the outer surface of a manufacturing tool to fill such a cavity.Then, a substrate is introduced onto the outer surface of the manufacturing tool above the filled cavity, so that the slurry wets one major surface of the substrate to form an intermediate article.Then, before the intermediate article is separated from the outer surface of the manufacturing tool, the binder is cured to form a coated structured abrasive article.Then, the coated structured abrasive article is removed from the surface of the manufacturing tool.

[0028] In another embodiment, a structured abrasive article can be made by first introducing a flowable and hardenable slurry containing a mixture of a binder precursor and multiple minerals onto the front surface of a substrate, so that the slurry wets the front surface of the substrate and forms an intermediate article. The slurry is then introduced onto the support side of the intermediate article against the outer surface of a production tool having multiple cavities on its outer surface, so that the cavities are filled. The binder precursor is then hardened before the intermediate article is separated from the outer surface of the production tool to form a coated structured abrasive article. The coated structured abrasive article is then removed from the surface of the production tool.

[0029] In both of the methods described, in one embodiment, the steps are performed sequentially, providing an efficient method of making the structured abrasive articles of the present invention.

[0030] In practice, structured abrasive articles are used as cleaning articles. Cleaning articles can take a variety of forms, including, but not limited to, wiping structures, hand pads, or items with handles. In the wiping structure shown in Figure 1, the cleaning article comprises abrasive composites and a substrate. When in a wiping form, the substrate may comprise a substantially thin and flexible material, such as, but not limited to, a nonwoven fabric, a woven fabric, a foam, or the like.

[0031] When the cleaning article is in the form of a hand pad, as shown in FIG. 2, the structured abrasive article may be attached to a substrate, such as a conformable material, which allows the user to better grip the cleaning article. Any material that allows the structured abrasive article to conform around the surface to be cleaned can be used. In one embodiment, the substrate can include, but is not limited to, a foam or soft polymer network, including rubber / elastomer or gel materials. This allows the user to better manipulate the structured abrasive article for more effective cleaning. In such a configuration, the cleaning article includes a first surface of the substrate and abrasive composites disposed adjacent to a second surface of the substrate, which are disposed adjacent to the foam layer. The foam layer may be attached to the substrate by any means known to those skilled in the art, including, but not limited to, mechanical or adhesive means.

[0032] In use, the structured abrasive article may be attached to a grip or handle, as seen in FIG. 3. The structured abrasive article may be permanently or removably attached to the grip or handle by an attachment mechanism. The grip or handle may be attached to the structured abrasive article by any means known to those skilled in the art. Exemplary attachment methods include mechanical or adhesive means. One exemplary mechanical attachment mechanism includes using plastic snaps. For example, the structured abrasive article can be attached to the grip or handle by engaging the insertable portion of the grip or handle with a shoe or cup attached to the structured abrasive article. The shoe or cup may be attached to the structured abrasive article by adhesive or mechanical means. To effect this engagement, the user inserts the insertable portion of the grip or handle into the cup or shoe of the structured abrasive article and pushes or applies force to guide the grip or handle firmly into / onto the cup or shoe. The user's force bends or presses inward at least one snap in the insertable portion of the grip or handle. This allows the insertable portion to slide into the cup or shoe. When the snaps are aligned with the corresponding slots on the cup or shoe, the snaps enter the slots and return to approximately their original, unflexed (relaxed) position. In this manner, the snaps engage with the slots on the cup or shoe attached to the structured abrasive article. In this engaged position, the snaps attach the structured abrasive article to the grip or handle and hold the structured abrasive article in place.

[0033] In one embodiment, when the structured abrasive article is attached to a grip or handle, an additional layer is placed between the structured abrasive article and the handle or grip. For example, a layer of foam, soft polymer, or other compatible material may be placed between the structured abrasive article and the grip or handle. In this embodiment, the foam layer can be attached to the structured abrasive article by any means known in the art, including, but not limited to, mechanical or adhesive means. The grip or handle is then attached (permanently or removably) to the foam layer. The overall structure of the cleaning article includes abrasive composites placed adjacent to a first surface of a substrate, a second surface of the substrate placed adjacent to the first surface of the foam layer, and a second surface of the foam layer placed adjacent to and attached to the handle or grip.

[0034] In some embodiments, the attachment mechanism includes an activation button or switch on the grip or handle. When the activation button is pressed, the structured abrasive article is ejected or released from its attachment to the grip or handle. In this embodiment, a user can activate the activation mechanism by activating the button or switch, and then insert the insertable portion of the grip or handle into the shoe or cup of the structured abrasive article. When the button or switch is activated, a snap on the grip or handle bends or pushes inward, allowing the structured abrasive article to slide easily onto the grip or handle. After placing the structured abrasive article on the grip or handle, the user releases or moves the button or switch back to its original position, causing the snap to engage with the slot on the shoe or cup, holding the structured abrasive article securely in place on the grip or handle.

[0035] To release the structured abrasive article from the grip or handle, the user activates a button or switch. This pushes or bends the snaps inward, generating enough force to release the snaps from the slots. The snaps are capable of bending such that they can bend inward, providing additional "elasticity" for releasing the structured abrasive article from the grip or handle. When the snaps are pushed inward, the structured abrasive article is released from the insertable portion. In this way, the structured abrasive article is easily removed from the grip or handle without the user having to touch the structured abrasive article. Various modifications and variations can be made to the specific embodiments described without departing from the spirit and scope of the present disclosure.

[0036] The grip or handle may be made from any suitable material. In some embodiments, the grip or handle may be molded. In some embodiments, the grip or handle is made from a polymeric material such as acrylonitrile butadiene (ABS), polyethylene, polypropylene, polycarbonate, or high-impact polystyrene. In some embodiments, the handle may feature an "overmolded" component designed to enhance the user's grip on the tool. Such components are generally made from urethane-based elastomers or hydrocarbon-based block copolymer elastomers such as styrene-isoprene-styrene (SIS), styrene-butadiene-styrene (SBS), or styrene-ethylene-butylene-styrene (SEBS) materials. [Example]

[0037] The present invention is described in more detail in the following examples, which are for purposes of illustration only, since numerous modifications and variations within the scope of the invention will become apparent to those skilled in the art. Unless otherwise noted, all parts, percentages, and ratios reported in the following examples are by weight.

[0038] [Table 1]

[0039] Test Method Article cleaning effectiveness test (food stain cleaning) The warewashing efficacy test was conducted in a manner generally similar to that described in U.S. Patent No. 5,626,512 (Palaikis et al.). A 5 mm thick, 4 inch diameter stainless steel disc was coated with a food soil mixture made from 120 grams of milk, 60 grams of cheddar cheese, 120 grams of hamburger, 120 grams of tomato juice, 120 grams of cherry juice, 20 grams of flour, and 100 grams of granulated sugar, as well as one egg. The coated panel was baked in an oven at 230°C for one hour. The above coating and curing process was repeated three times to obtain a uniform coating on the panel. An acceptable food soil coating weight is equal to at least 0.9 grams. A 1 inch (approximately 1 inch) disc containing precision-molded abrasive composites fixed in a polymer film was used. 2 A test sample of 1.5 mm was cut from a larger sample of each abrasive article. The sample was placed on a single finger (approximately 0.08 inches) with a 5 pound weight on it. 2 The food-soil disc was contacted by force transmitted through a 1-inch thick piece of foam with a contact area of ​​1.0 mm (having a contact area with the sample of 1.0 mm). The assembly including the weight, fingers, foam, and abrasive sample was manually pushed / pulled over the coated panel using the track as a guide until the abraded area of ​​the coated panel was clean (until no coated material was visibly left on the panel). The travel length was 2 inches. The number of cycles required to produce a clean panel (a back and forth movement equals one cycle at a speed of approximately 45 cycles per minute) was recorded.

[0040] Scratch test procedure Approximately 3 cm containing precision-molded abrasive composites fixed in a polymer film 2Test samples measuring 1 / 4" were cut from larger samples of each abrasive article. The test sample was pressed into the test surface with the face of the tester's thumb, applying approximately 5 pounds of force and pulling back and forth across the surface for 5 seconds. The surfaces were then visually inspected for changes in surface finish. The poly(tetrafluoroethylene) (PTFE) surface tested was the surface of a nonstick frying pan, and the chrome surface was the surface of a drip pan for an electric coil cooking range.

[0041] Durability test (grinding weight loss) This test was used to determine the durability of abrasive articles; it involved rubbing each abrasive article sample back and forth on an abrasive material, with the percent weight loss recorded after the test. A lower percent weight loss indicated a more durable product. The abrasion test was conducted in a manner generally similar to that described in U.S. Pat. No. 5,681,361 (Sanders, Jr.). The test sample size was 2.5 inches by 9.0 inches (63.5 mm by 228.6 mm). The downward load applied to the test sample was 2.25 kg. The percent weight loss was determined after 100 linear passes back and forth (travel length was approximately 14 inches) over a conditioned (run-in) M125 Diamond Cloth belt (3M Company, St. Paul, MN) in the presence of warm water.

[0042] Examples EX1 to EX7 Preparation of binder precursor with dispersed soft mineral particles The liquid ingredients AUDA, TMPTA, PI, DISP, and CA were added to a SPEEDMIXER cup and mixed for 60 seconds at 2400 rpm in a DAC400.2 VAC-P SPEEDMIXER (FlackTek, Inc., Landrum, SC). TA and PCC were then added to the cup to complete a total batch size of 200 grams, and the mixture was mixed for 30 seconds at 1200 rpm. The mixture was then placed in a 150°F (66°C) oven for 30 minutes, after which it was mixed for 3 minutes at 2400 rpm to obtain a liquid slurry of the binder precursor and soft mineral particles.

[0043] [Table 2]

[0044] Preparation of Coated Abrasive Articles Coated abrasive articles were prepared using methods similar to those described in U.S. Pat. No. 5,152,917 (Pieper et al.) (see, e.g., Examples 1-5) and U.S. Pat. No. 7,267,000 (Collins et al.) (see, e.g., column 11, lines 9-34). A production tool was provided with an outer surface having a plurality of cavities corresponding to the inverse shape of the desired abrasive composite. Each of the cavities had a shape resembling a pyramid with a base length of 400-700 microns and a height of 450 microns. For each of the formulations in Examples EX1-X7, a liquid slurry of binder precursor and a plurality of soft mineral particles was coated into the cavities of the production tool. A backing was then introduced onto the outer surface of the production tool over the filled cavities so that the slurry wetted one major surface of the backing to form an intermediate article. The backing was a polyester film (3 mil thick) with a 0.81 mil thick poly(ethylene-co-acrylic acid) primer layer that had been corona-treated to prime the film. The production tool containing the slurry and soft mineral particles was then exposed to UV radiation to cure the binder precursor.The abrasive article was then removed from the production tool.

[0045] The abrasive articles of Examples EX1-EX7 were then tested for cleaning efficacy (food soil cleaning), marring properties, and durability (abrasive weight loss) using the test methods described above. For comparison, Comparative Example CE1 was also tested. Comparative Example CE1 was a 1-inch thick melamine-formaldehyde thermoset standard density foam obtained from BASF. The results are shown in Table 2.

[0046] [Table 3]

[0047] It should be noted that the non-abrasive properties of the abrasive article can be adjusted by adjusting the UADA:TMPA and / or TA:PCC ratios, with an increase in each ratio resulting in a softer and more conformable abrasive article that is generally less abrasive but also requires more effort when used to clean a surface.

[0048] Various modifications and alterations to the present disclosure will become apparent to those skilled in the art without departing from the scope and spirit of the disclosure. It is understood that the present disclosure is not intended to be unduly limited by the exemplary embodiments and examples set forth herein, and that such examples and embodiments are presented merely as examples within the scope of the present disclosure, which is intended to be limited only by the claims set forth herein as follows. All references cited in this disclosure are incorporated herein by reference in their entirety. The present invention includes the following aspects. (1) An abrasive composite comprising: When polymerized, the glass transition temperature (T g ) and a first crosslinkable binder component having a modulus of elasticity of less than about 150 MPa; T above room temperature g a second crosslinkable binder component having a material capable of initiating addition polymerization; and particulate particles having a Mohs hardness value of about 3 or less. (2) The abrasive composite according to item 1, wherein the first crosslinkable binder component comprises a urethane diacrylate or triacrylate. (3) The abrasive composite of item 1, wherein when polymerized, the first crosslinkable binder component has an elongation at break of greater than about 25%. (4) The abrasive composite according to item 1, wherein the second crosslinkable binder component comprises a difunctional or trifunctional acrylate. (5) The abrasive composite according to item 1, wherein the material capable of initiating addition polymerization comprises a UV photoinitiator. (6) The particulate particles have a diameter of less than about 50 microns. 90 Item 1. The abrasive composite of item 1, comprising an inorganic mineral having the formula: (7) The abrasive composite according to item 1, wherein the abrasive composite comprises about 15% to about 35% by weight of the first crosslinkable binder component. (8) The abrasive composite according to item 1, wherein the abrasive composite comprises about 8% to about 28% by weight of the second crosslinkable binder component. (9) The abrasive composite according to item 1, wherein the abrasive composite comprises about 0.5% to about 2% by weight of the material capable of initiating addition polymerization. (10) The abrasive composite according to item 1, wherein the abrasive composite comprises about 26% to about 80% by weight of the particulate particles. (11) The abrasive composite of item 1, wherein the particulate particles comprise gypsum. (12) The abrasive composite according to item 1, comprising at least first particulate particles and second particulate particles. (13) A structured abrasive article, A substrate; and an abrasive composite adhered to the backing, the abrasive composite comprising: When polymerized, the glass transition temperature (T g ) and a first crosslinkable binder component having a modulus of elasticity of less than about 150 MPa; T above room temperature g a second crosslinkable binder component having a material capable of initiating addition polymerization; and fine particle having a Mohs hardness value of about 3 or less. (14) The structured abrasive article of item 13, wherein the structured abrasive article is attached to a handle. (15) The structured abrasive article of item 13, wherein the structured abrasive article is removably attached to a handle. (16) The structured abrasive article of item 14, wherein the structured abrasive article is attached to the handle by mechanical means. (17) The structured abrasive article of item 14, wherein the structured abrasive article is attached to the handle by an adhesive. (18) The structured abrasive article of item 13, further comprising a conformable layer disposed adjacent to the backing. (19) The structured abrasive article of item 18, further comprising a handle, the conformable layer being disposed between the structured abrasive article and the handle.

Claims

1. 1. An abrasive composite comprising: a first crosslinkable binder component comprising a urethane diacrylate or triacrylate that is rubbery when polymerized and has a modulus of elasticity of less than about 150 MPa; a second crosslinkable binder component comprising a di- or tri-functional acrylate that is glassy when polymerized; and a material capable of initiating addition polymerization; and particulate particles having a Mohs hardness value of about 3 or less.

2. 10. The abrasive composite of claim 1, wherein when polymerized, the first crosslinkable binder component has an elongation at break of greater than about 25%.

3. The fine particulate particles have a d of less than about 50 microns ９０ 10. The abrasive composite of claim 1, comprising an inorganic mineral having the formula:

4. The abrasive composite of claim 1 , wherein the particulate particles comprise gypsum.

5. 1. A structured abrasive article comprising: A substrate; and an abrasive composite adhered to the backing, the abrasive composite comprising: a first crosslinkable binder component comprising a urethane diacrylate or triacrylate that is rubbery when polymerized and has a modulus of elasticity of less than about 150 MPa; a second crosslinkable binder component comprising a di- or tri-functional acrylate that is glassy when polymerized; and a material capable of initiating addition polymerization; and fine particulate particles having a Mohs hardness value of about 3 or less.

6. The structured abrasive article of claim 5 , wherein the structured abrasive article is attached to a handle.

7. The structured abrasive article of claim 5 further comprising a conformable layer disposed adjacent to the backing.

8. The structured abrasive article of claim 7 , further comprising a handle, the conformable layer being disposed between the structured abrasive article and the handle.

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