Carboxylic acid ester color-stabilized phenolic bound abrasive products and methods for making same

Abstract

Described is a color-stable abrasive article that includes a phenolic resin binder; a color stabilizer, a colorant, and abrasive grains. The color stabilizer includes at least one carboxylic acid ester. The color-stable abrasive article is formed by a method including the steps of blending a resole and a color stabilizer to form a resole composition; contacting a plurality of abrasive particles with the resole composition; and curing the resole composition to produce the color-stable abrasive article. Thus provided are color stabilized phenolic bound abrasives and a method for making such abrasives that resist color change over time and upon exposure to high temperature and maintain the mechanical strength of a phenolic resin.

1 . A color-stable abrasive article, comprising:
 a) a binder comprising a phenolic resin;   b) a color-stabilizer that includes at least one carboxylic acid ester; and   c) abrasive grains.   
   
   
       2 . The color-stable abrasive article of  claim 1 , wherein the color-stabilizer includes a compound selected from the group consisting of carboxylic acid esters, esters, carboxylic acids, compounds including a dione group, compounds including an acrylic group, and combinations of thereof. 
   
   
       3 . The color-stable abrasive article of  claim 2 , wherein the color-stabilizer includes a lactate. 
   
   
       4 . The color-stable abrasive article of  claim 2 , wherein the color-stabilizer includes at least one compound selected from the group consisting of heptanoic acid, lactic acid, ethyl acetoacetate, 2,2,5-trimethyl-1-3-dioxane-4-6-dione, ethyl lactate, and 2-(dimethylamino)ethylmethacrylate. 
   
   
       5 . The color-stable abrasive article of  claim 1 , wherein the phenolic resin is a resole. 
   
   
       6 . The color-stable abrasive article of  claim 1 , wherein the color-stabilizer is present in an amount between about 1% and about 40% by weight of the phenolic resin. 
   
   
       7 . The color-stable abrasive article of  claim 6 , wherein the color-stabilizer is present in an amount between about 4% and about 10% by weight of the phenolic resin. 
   
   
       8 . The color-stable abrasive article of  claim 1 , further comprising a support member. 
   
   
       9 . The color-stable abrasive article of  claim 1 , further comprising a co-solvent. 
   
   
       10 . The color-stable abrasive article of  claim 9 , wherein the co-solvent is glycol. 
   
   
       11 . The color-stable abrasive article of  claim 1 , further comprising a curing additive. 
   
   
       12 . The color-stable abrasive article of  claim 11 , wherein the curing additive includes one or more additives selected from the group of peroxide and a UV photo-initiator. 
   
   
       13 . The color-stable abrasive article of  claim 1 , having no visually perceptible color change after about 8 hours of curing at about 235° F. relative to the same article after about 2 hours of curing at about 235° F. 
   
   
       14 . The color-stable abrasive article of  claim 1 , further comprising a colorant. 
   
   
       15 . The color-stable abrasive article of  claim 1 , wherein the article is a bonded, structured, or coated abrasive article. 
   
   
       16 . The color-stable abrasive article of  claim 15 , wherein the phenolic resin binder and color stabilizer are present in at least one layer selected from the group consisting of a binder-abrasive layer, a backsize coat, a presize coat, a make coat, a size coat, and a supersize coat. 
   
   
       17 . A method of making a color-stable abrasive article, comprising the steps of:
 a) blending a resole and a color-stabilizer comprising at least one carboxylic acid ester to form a resole composition;   b) contacting a plurality of abrasive particles with the resole composition; and   c) curing the resole composition to produce the color-stable abrasive article.   
   
   
       18 . A method for abrading a work surface, comprising applying color-stable abrasive article to a work surface in an abrading motion to remove a portion of the work surface, the abrasive product including:
 a) a binder comprising a phenolic resin;   b) a color-stabilizer that includes a compound selected from the group consisting of carboxylic acid esters, esters, carboxylic acids, compounds including a dione group, compounds including an acrylic group, and combinations of thereof; and   c) abrasive grains.