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 method of fabricating a composite abrasive body 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.   
     
     
         2 . The method according to  claim 1 , 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. 
     
     
         3 . The method according to  claim 2 , 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. 
     
     
         4 . The method according to  claim 1 , wherein the radical initiator is an organic peroxide. 
     
     
         5 . The method according to  claim 1 , wherein the radical initiator is benzoyl peroxide. 
     
     
         6 . The method according to  claim 1 , wherein the adhesive has a pasty consistency. 
     
     
         7 . A method of fabricating a composite abrasive body 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.   
     
     
         8 . The method according to  claim 7 , wherein the polyisocyanate is selected from polyurethane prepolymers. 
     
     
         9 . The method according to  claim 8 , wherein the polyurethane prepolymers are synthesized from polyisocyanates and polyols. 
     
     
         10 . The method of fabricating the composite abrasive body according to  claim 7 , 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. 
     
     
         11 . The method according to  claim 9 , wherein the polyol is chosen from the group consisting of polyoxyalkylene polyols. 
     
     
         12 . The method according to  claim 7 , wherein the adhesive has a pasty consistency. 
     
     
         13 . A method of fabricating of a composite abrasive body 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.   
     
     
         14 . The method according to  claim 13 , wherein the mixing, application, contacting, and curing steps are carried out at a temperature between 10° C. and 180° C. 
     
     
         15 . The method according to  claim 13 , wherein the mixing, application, contacting, and curing steps are carried out at a temperature between 20° C. and 80° C. 
     
     
         16 . The method according to  claim 13 , wherein the mixing, application, contacting, and curing steps are carried out at a temperature between 20° C. and 40° C. 
     
     
         17 . The method according to  claim 13 , wherein the mixing, application, contacting, and curing steps are carried out at room temperature. 
     
     
         18 . The method according to  claim 13 , wherein a surface of the abrasive product support or a surface of the abrasive product undergo chemical or physical pretreatment before bonding. 
     
     
         19 . The method according to  claim 13 , 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. 
     
     
         20 . The method according to  claim 19 , 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. 
     
     
         21 . The method according to  claim 20 , wherein the flap-shaped abrasive members overlap in a fan-like or shingle-like fashion.