Precisely shaped particles and method of making the same

• Main Authors: GARY L. HOLMES, SCOTT R. CULLER, DAVID H. HARDY
• Format: Patent
• Language: English
• Published: 10.07.1996
• Edition: 6
• Subjects: ADHESIVES; CHEMISTRY; DYES; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR; GRINDING; LAUNDERING; MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FORELSEWHERE; METALLURGY; MISCELLANEOUS APPLICATIONS OF MATERIALS; MISCELLANEOUS COMPOSITIONS; NATURAL RESINS; PAINTS; PERFORMING OPERATIONS; POLISHES; POLISHING; TEXTILES; TOOLS FOR GRINDING, BUFFING, OR SHARPENING; TRANSPORTING; TREATMENT OF TEXTILES OR THE LIKE; WALL, FLOOR OR LIKE COVERING MATERIALS, e.g. LINOLEUM,OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF AFIBROUS WEB COATED WITH A LAYER OF MACROMOLECULARMATERIAL

Precisely shaped particles and methods for making these particles. The method of this invention comprises the steps of: (a) providing a production tool having a three-dimensional body which has at least one continuous surface, said surface containing at least one opening formed in said continuous surface, said at least one opening providing access to a cavity in said three-dimensional body; (b) providing a dispensing means capable of introducing a binder precursor comprising a thermosetting resin into said at least one cavity through said at least one opening; (c) providing a means, within a curing zone, for at least partially curing said binder precursor; (d) introducing said binder precursor into at least a portion of said at least one cavity; (e) continuously moving said at least one cavity through said curing zone to at least partially cure said binder precursor to provide a solidified, handleable binder having a shape corresponding to that portion of the cavity into which the binder precursor had been introduced; (f) removing said binder from said at least one cavity; and (g) converting said binder to form a precisely shaped particle. Steps (f) and (g) can be conducted simultaneously. The particles can be bonded together to form a shaped mass, e.g., a wheel; alternatively, the particles can be bonded to a backing to form a coated abrasive article; or the particles can be bonded into a fibrous, nonwoven substrate to form a non-woven abrasive article.