Composite abrasive bodies

Abstract

Composite abrasive bodies, which include abrasive product supports, abrasive particles and cured adhesives bonding the abrasive product supports and the abrasive products, are provided. The cured adhesives may be two-component polyurethane or (meth)acrylate adhesives. In addition, methods for preparing the composite abrasive bodies are also provided.

1 . A composite abrasive body, comprising:
 at least one abrasive product support,   at least one abrasive product having abrasive particles present on a surface of the abrasive product, and   at least one cured adhesive, which bonds the abrasive product support and the abrasive product together,   wherein the cured adhesive is a two-component polyurethane adhesive or a two-component (meth)acrylate adhesive.   
   
   
       2 . The composite abrasive body according to  claim 1 , wherein the abrasive particles are present only on one side of the abrasive product. 
   
   
       3 . The composite abrasive body according to  claim 1 , wherein the abrasive product is a flap-shaped abrasive member. 
   
   
       4 . The composite abrasive body according to  claim 3 , wherein the flap-shaped abrasive member is constructed from at least one cloth or paper, at least one binder, and abrasive particles. 
   
   
       5 . The composite abrasive body according to  claim 4 , wherein the surface of the abrasive member having the abrasive particles is partially surrounded by a binder. 
   
   
       6 . The composite abrasive body according to  claim 4 , wherein the binder is a polymer. 
   
   
       7 . The composite abrasive body according to  claim 6 , wherein the polymer is a reaction product based on a member of the group consisting of polyepoxides, polyurethanes and polyphenols. 
   
   
       8 . The composite abrasive body according to  claim 1 , wherein the abrasive product support is a member of the group consisting of circular discs, wheels and belts. 
   
   
       9 . The composite abrasive body according to  claim 8 , wherein the abrasive product is bonded to the abrasive product support on a largest area surface of the abrasive product support. 
   
   
       10 . The composite abrasive body according to  claim 9 , wherein the abrasive product support is a member of the group consisting of circular discs and wheels, and the abrasive product is bonded to the abrasive product support in a radial direction of the abrasive product support. 
   
   
       11 . The composite abrasive body according to  claim 8 , wherein the abrasive product support is a member of the group consisting of circular discs and wheels, and the abrasive product is bonded to a peripheral surface of the abrasive product support. 
   
   
       12 . The composite abrasive body according to  claim 11 , wherein the abrasive product is bonded to the peripheral surface of the abrasive product support in a radial orientation. 
   
   
       13 . The composite abrasive body according to  claim 1 , wherein a plurality of abrasive products is bonded to the abrasive product support and the plurality of abrasive products are disposed to partially overlap each other. 
   
   
       14 . The composite abrasive body according to  claim 1 , wherein the polyurethane or (meth)acrylate adhesive is cured at a temperature between 10° C. and 180° C. 
   
   
       15 . The composite abrasive body according to  claim 14 , wherein the polyurethane or (meth)acrylate adhesive is cured at a temperature between 20° C. and 80° C. 
   
   
       16 . The composite abrasive body according to  claim 15 , wherein the polyurethane or (meth)acrylate adhesive is cured at a temperature between 20° C. and 40° C. 
   
   
       17 . The composite abrasive body according to  claim 16 , wherein the polyurethane or (meth)acrylate adhesive is cured at room temperature. 
   
   
       18 . The composite abrasive body according to  claim 1 , wherein the cured adhesive is a two-component (meth)acrylate adhesive obtained by mixing two components, wherein
 a first component of the adhesive contains at least one (meth)acrylate monomer, and   a second component contains at least one radical initiator.   
   
   
       19 . The composite abrasive body according to  claim 18 , wherein the (meth)acrylate monomer is selected from the group consisting of isobornyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, diethylene glycol di(meth)acrylate, epoxy (meth)acrylate, trimethylol tri(meth)acrylate, and mixtures thereof. 
   
   
       20 . The composite abrasive body according to  claim 19 , wherein the (meth)acrylate monomer is an epoxy (meth)acrylate synthesized from (meth)acrylic acid and a compound selected from the group consisting of bisphenol-A diglycidyl ether, bisphenol-A diglycidyl ether oligomers, bisphenol-A and ethoxylated bisphenol-A. 
   
   
       21 . The composite abrasive body according to  claim 18 , wherein the radical initiator is an organic peroxide. 
   
   
       22 . The composite abrasive body according to  claim 18 , wherein the radical initiator is benzoyl peroxide. 
   
   
       23 . A composite abrasive body according to  claim 1 , wherein the cured adhesive is a two-component polyurethane adhesive obtained by mixing two components, wherein
 a first component contains at least one polyol or one polyamine, and   a second component contains at least one polyisocyanate.   
   
   
       24 . The composite abrasive body according to  claim 23 , wherein the polyisocyanate is selected from polyurethane prepolymers. 
   
   
       25 . The composite abrasive body according to  claim 24 , wherein the polyurethane prepolymers are synthesized from polyisocyanates and polyols. 
   
   
       26 . The composite abrasive body according to  claim 23 , wherein the polyisocyanate is selected from the group consisting 1,6-hexamethylene diisocyanate (HDI), 2,4- and 2,6-toluylene diisocyanate (TDI), 4,4′-diphenylmethane diisocyanate (MDI), 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane, isomers thereof, mixtures thereof. 
   
   
       27 . The composite abrasive body according to  claim 24 , wherein the polyol is chosen from the group consisting of polyoxyalkylene polyols. 
   
   
       28 . A method of fabricating the composite abrasive body according to  claim 1  comprising:
 bonding the abrasive support and the abrasive product together with a two-component (meth)acrylate adhesive, wherein   the two component (meth)acrylate adhesive consists of a first component which contains at least one (meth)acrylate monomer, and a second component, which contains at least one radical initiator.   
   
   
       29 . The method according to  claim 28 , wherein the (meth)acrylate monomer is selected from the group consisting of isobornyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, diethylene glycol di(meth)acrylate, epoxy (meth)acrylate, trimethylol tri(meth)acrylate, and mixtures thereof. 
   
   
       30 . The method according to  claim 29 , wherein the (meth)acrylate monomer is an epoxy (meth)acrylate synthesized from (meth)acrylic acid and a compound selected from the group consisting of bisphenol-A diglycidyl ether, bisphenol-A diglycidyl ether oligomers, bisphenol-A and ethoxylated bisphenol-A. 
   
   
       31 . The method according to  claim 28 , wherein the radical initiator is an organic peroxide. 
   
   
       32 . The method according to  claim 28 , wherein the radical initiator is benzoyl peroxide. 
   
   
       33 . The method according to  claim 28 , wherein the adhesive has a pasty consistency. 
   
   
       34 . A method of fabricating the composite abrasive body according to  claim 1  comprising:
 bonding the abrasive support and the abrasive product together with a two-component polyurethane adhesive, wherein the two-component polyurethane adhesive consists of a first component, which contains at least one polyamine or one polyol, and a second component, which contains at least one polyisocyanate.   
   
   
       35 . The method according to  claim 34 , wherein the polyisocyanate is selected from polyurethane prepolymers. 
   
   
       36 . The method according to  claim 35 , wherein the polyurethane prepolymers are synthesized from polyisocyanates and polyols. 
   
   
       37 . The method of fabricating the composite abrasive body according to  claim 34 , wherein the polyisocyanate is selected from the group consisting 1,6-hexamethylene diisocyanate (HDI), 2,4- and 2,6-toluylene diisocyanate (TDI), 4,4′-diphenylmethane diisocyanate (MDI), 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane, isomers thereof, mixtures thereof. 
   
   
       38 . The method according to  claim 36 , wherein the polyol is chosen from the group consisting of polyoxyalkylene polyols. 
   
   
       39 . The method according to  claim 34 , wherein the adhesive has a pasty consistency. 
   
   
       40 . A method of fabricating of the composite abrasive body according to  claim 1 , comprising:
 mixing the two components of a two-component polyurethane or (meth)acrylate adhesive;   applying the mixed adhesive to the abrasive product support;   contacting the mixed adhesive and at least one abrasive product;   -curing the adhesive.   
   
   
       41 . The method according to  claim 40 , wherein the mixing, application, contacting, and curing steps are carried out at a temperature between 10° C. and 180° C. 
   
   
       42 . The method according to  claim 40 , wherein the mixing, application, contacting, and curing steps are carried out at a temperature between 20° C. and 80° C. 
   
   
       43 . The method according to  claim 40 , wherein the mixing, application, contacting, and curing steps are carried out at a temperature between 20° C. and 40° C. 
   
   
       44 . The method according to  claim 40 , wherein the mixing, application, contacting, and curing steps are carried out at room temperature. 
   
   
       45 . The method according to  claim 40 , wherein a surface of the abrasive product support or a surface of the abrasive product undergo chemical or physical pretreatment before bonding. 
   
   
       46 . The method according to  claim 40 , wherein the abrasive product is a flap-shaped abrasive member and the flap-shaped abrasive member is inserted into the mixed abrasive and applied to the abrasive product support in an essentially vertical orientation with respect to the abrasive product support surface, so that part of the surface of the flap-shaped abrasive member is covered by adhesive. 
   
   
       47 . The method according to  claim 46 , wherein a plurality of flap-shaped abrasive members are inserted next to each other into uncured adhesive and then are taken from an essentially vertical orientation to a tilted orientation. 
   
   
       48 . The method according to  claim 47 , wherein the flap-shaped abrasive members overlap in a fan-like or shingle-like fashion.