Acrylate 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 acrylate. 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 acrylate; and   c) abrasive grains.   
   
   
       2 . The color-stable abrasive article of  claim 1 , wherein the phenolic resin is a resole. 
   
   
       3 . The color-stable abrasive article of  claim 1 , wherein the color-stabilizer is present in an amount between about 2% and about 60% by weight. 
   
   
       4 . The color-stable abrasive article of  claim 1 , wherein the color-stabilizer is present in an amount between about 7% and about 15% by weight. 
   
   
       5 . The color-stable abrasive article of  claim 1 , further comprising a support member. 
   
   
       6 . The color-stable abrasive article of  claim 1 , wherein the color-stabilizer is an acrylate selected from the group consisting of ethyl acrylate, epoxy acrylate, pentacrylate, and trimethylolpropane triacrylate (TMPTA). 
   
   
       7 . The color-stable abrasive article of  claim 1 , wherein the color-stabilizer includes a water soluble acrylate resin. 
   
   
       8 . The color-stable abrasive article of  claim 7 , wherein the water soluble acrylate resin is ethoxylated trimethylolpropane triacrylate. 
   
   
       9 . The color-stable abrasive article of  claim 7 , 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 , wherein the color-stabilizer includes a water insoluble acrylate resin. 
   
   
       12 . The color-stable abrasive article of  claim 11 , wherein the water insoluble acrylate resin is present in an amount between about 2% and about 15% by weight. 
   
   
       13 . The color-stable abrasive article of  claim 6 , further comprising a curing additive. 
   
   
       14 . The color-stable abrasive article of  claim 13 , wherein the curing additive includes one or more additives selected from the group of peroxide and a UV photo-initiator. 
   
   
       15 . The color-stable abrasive article of  claim 13 , wherein the acrylate is present in an amount between about 5% and about 60% by weight. 
   
   
       16 . The color-stable abrasive article of  claim 13 , wherein the acrylate is present in an amount between about 10% and about 60% by weight. 
   
   
       17 . The color-stable abrasive article of  claim 6 , wherein the acrylate resin is capable of reacting with the phenolic resin. 
   
   
       18 . 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. 
   
   
       19 . The color-stable abrasive article of  claim 1 , further comprising a colorant. 
   
   
       20 . The color-stable abrasive article of  claim 1 , wherein the article is a bonded, structured, or coated abrasive article. 
   
   
       21 . The color-stable abrasive article of  claim 20 , 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. 
   
   
       22 . 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 acrylate 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.   
   
   
       23 . 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 at least one acrylate; and   c) abrasive grains.