Phenolic-Polyurethane Binders for Durable Abrasive Articles
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Solution Overview
Problem
There is a need to improve the cost, performance, and/or life of abrasive articles such as coated abrasives and nonwoven abrasives.
Innovation Solution
The use of a binder material comprising a cured reaction product of phenolic resin and an aqueous dispersion of polyurethane, with specific weight ratios, to secure abrasive particles to a substrate, enhancing toughness and brittleness/stiffness properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional binder materials are used to secure abrasive particles to the substrate, then the abrasive article can be manufactured with standard properties, but the toughness and brittleness/stiffness properties are insufficient
Solution Approach 1:
The patent applies composite materials by combining phenolic resin and polyurethane dispersion in a binder system. This composite binder material integrates the toughness of polyurethane with the stiffness and heat resistance of phenolic resin, achieving balanced mechanical properties that resolve the contradiction between toughness and brittleness/stiffness requirements for abrasive articles.
Solution Approach 2:
The patent employs parameter changes by systematically varying the ratio of phenolic resin to polyurethane dispersion (from 90:10 to 10:90) to optimize the balance between toughness and brittleness/stiffness. This parametric approach allows tuning of the binder properties to achieve desired durability and performance characteristics for different abrasive application requirements.
2Strength
If phenolic resin and polyurethane dispersion are combined in specific ratios, then toughness and brittleness/stiffness are enhanced, but the binder formulation complexity increases
Solution Approach 1:
The patent manages formulation complexity through systematic parameter changes by defining specific ratio ranges (90:10 to 10:90 phenolic resin to polyurethane) rather than exploring unlimited compositional space. This parametric framework simplifies the formulation process while still achieving enhanced toughness and brittleness/stiffness properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The phenolic/polyurethane binder materials provide improved durability and performance characteristics to abrasive articles, enhancing their effectiveness in abrading and finishing applications.
Implementation Method 1
the at least one binder material comprises a cured reaction product of components comprising: a) at least one phenolic resin; and b) an aqueous dispersion of at least one polyurethane
Implementation Method 2
the curable make resin is at least partially cured (that is, crosslinked) to adhere the abrasive particles to the backing
Implementation Method 3
the abrading action of the belt on a workpiece (e.g., wood) increases the load on the drive motor used to drive the belt
Data Source
Figure 1~3B
AI summary
An abrasive article comprises abrasive particles secured to a substrate by at least one binder material. The at least one binder material comprises a cured reaction product of components comprising: a) at least one phenolic resin; and b) an aqueous dispersion of at least one polyurethane, wherein, based on the total solids weight of components a) and b), the components comprise 56 to 91 percent by weight of component a) and 44 to 9 percent by weight of component b). Methods of making and using the abrasive articles are also disclosed.