CN112839773A

CN112839773A - Abrasive article with improved performance

Info

Publication number: CN112839773A
Application number: CN201980067212.2A
Authority: CN
Inventors: 雅各布·S·贝弗里奇; 琼·W·施罗德
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2018-10-15
Filing date: 2019-10-04
Publication date: 2021-05-25
Anticipated expiration: 2039-10-04
Also published as: EP3867013A1; TW202104519A; CN112839773B; US20210379731A1; WO2020079522A1

Abstract

The present disclosure relates to an abrasive article. The abrasive article (10) includes a nonwoven web (12). The nonwoven web (12) includes a fibrous or filament component (18). The nonwoven web (12) also includes a first major surface (14) and a second major surface (16). The thickness of the nonwoven web (12) is defined from the first major surface to the second major surface (16). The abrasive article also includes a plurality of shaped abrasive particles (22) dispersed in at least a portion of the nonwoven web (12). The abrasive article also includes a heat-activated water-forming inorganic component dispersed in the nonwoven web (12).

Description

Abrasive article with improved performance

Background

Nonwoven abrasive articles typically have a nonwoven web (e.g., a lofty open fibrous web), abrasive particles, and a binder material (often referred to as a "binder") that binds the fibers within the nonwoven web to each other and secures the abrasive particles to the nonwoven web.

Disclosure of Invention

Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a nonwoven web. The nonwoven web comprises a fibrous or filament component. The nonwoven web also includes a first major surface and a second major surface. The thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed in at least a portion of the nonwoven web. The abrasive article further includes a thermally activated water-forming inorganic component dispersed in the nonwoven web.

Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a nonwoven web. The nonwoven web comprises a fibrous or filament component. The nonwoven web also includes a first major surface and a second major surface. The thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed in at least a portion of the nonwoven web. The abrasive article further includes a hydrated aluminum compound dispersed in the nonwoven web.

Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a nonwoven web. The nonwoven web comprises a fibrous or filament component. The nonwoven web also includes a first major surface and a second major surface. The thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed in at least a portion of the nonwoven web. The abrasive article further includes a hydrated aluminum compound dispersed in the nonwoven web. About 5% to about 70% of the plurality of shaped abrasive particles comprise tips oriented in a direction substantially perpendicular to a line passing through the first major surface and the second major surface.

Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a nonwoven web. The nonwoven web comprises a fibrous or filament component. The nonwoven web also includes a first major surface and a second major surface. The thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed in at least a portion of the nonwoven web. The abrasive article further includes a hydrated aluminum compound dispersed in the nonwoven web. A portion of the plurality of shaped abrasive particles comprising a face oriented in a direction substantially perpendicular to a line passing through the first major surface and the second major surface is in a range of about 5% to about 70% of the plurality of shaped abrasive particles.

According to various embodiments of the present disclosure, a slurry comprises a plurality of shaped abrasive particles. The slurry also contains a thermally activated water-forming inorganic component. The slurry also contains a solvent, a lubricant, and a binder.

According to various embodiments of the present disclosure, a method of making an abrasive article is described. The abrasive article includes a nonwoven web. The nonwoven web comprises a fibrous or filament component. The nonwoven web also includes a first major surface and a second major surface. The thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed in at least a portion of the nonwoven web. The abrasive article further includes a thermally activated water-forming inorganic component dispersed in the nonwoven web. The method includes forming a nonwoven web of fibers or filaments. The method also includes perforating the web. The method also includes applying abrasive particles and a binder to the perforated web. The method also includes curing the binder to provide the abrasive article.

Drawings

The drawings are generally shown by way of example, and not by way of limitation, to the various embodiments discussed in this document.

FIG. 1 is a perspective view of an abrasive article.

FIG. 2 is a cross-sectional view of the abrasive article of FIG. 1 taken along section line 2-2.

Fig. 3A-3D are schematic illustrations of shaped abrasive particles having a planar triangular shape according to various embodiments.

Fig. 4A-4E are schematic illustrations of shaped abrasive particles having a tetrahedral shape, according to various embodiments.

Fig. 5 is a graph illustrating penetration depth of shaped abrasive particles in a nonwoven web according to various embodiments.

Fig. 6 is a graph illustrating penetration depth of shaped abrasive particles in a nonwoven web according to various embodiments.

Fig. 7 is a graph illustrating penetration depth of shaped abrasive particles in a nonwoven web according to various embodiments.

Detailed Description

Reference will now be made in detail to specific embodiments of the presently disclosed subject matter, examples of which are illustrated in the accompanying drawings. While the presently disclosed subject matter will be described in conjunction with the recited claims, it will be understood that the exemplary subject matter is not intended to limit the claims to the presently disclosed subject matter.

Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted to include not only about 0.1% to about 5%, but also include individual values (e.g., 1%, 2%, 3%, and 4%) and sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. Unless otherwise indicated, the expression "about X to Y" has the same meaning as "about X to about Y". Likewise, unless otherwise indicated, the expression "about X, Y or about Z" has the same meaning as "about X, about Y, or about Z".

In this document, the terms "a", "an" or "the" are used to include one or more than one unless the context clearly indicates otherwise. The term "or" is used to refer to a non-exclusive "or" unless otherwise indicated. The expression "at least one of a and B" has the same meaning as "A, B or a and B". Also, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid in the understanding of the document and should not be construed as limiting; information related to a section header may appear within or outside of that particular section.

In the methods described herein, various actions may be performed in any order, except when a time or sequence of operations is explicitly recited, without departing from the principles of the invention. Further, the acts specified may occur concurrently unless the express claim language implies that they occur separately. For example, the claimed act of performing X and the claimed act of performing Y may be performed simultaneously in a single operation, and the resulting process would fall within the literal scope of the claimed process.

As used herein, the term "about" can allow, for example, a degree of variability in the value or range, e.g., within 10%, within 5%, or within 1% of the stated value or limit of the range, and includes the exact stated value or range.

The term "substantially" as used herein refers to a majority or majority, such as at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

As used herein, "shaped abrasive particles" means abrasive particles having a predetermined or non-random shape. One process for making shaped abrasive particles, such as shaped ceramic abrasive particles, includes shaping precursor ceramic abrasive particles in a mold having a predetermined shape to produce ceramic shaped abrasive particles. The ceramic shaped abrasive particles formed in the mold are one of a class of shaped ceramic abrasive particles. Other processes for making other types of shaped ceramic abrasive particles include extruding precursor ceramic abrasive particles through orifices having a predetermined shape, stamping the precursor ceramic abrasive particles through openings in a printing screen having a predetermined shape, or stamping the precursor ceramic abrasive particles into a predetermined shape or pattern. In other examples, the shaped ceramic abrasive particles may be cut from a sheet into individual particles. Examples of suitable cutting methods include mechanical cutting, laser cutting, or water jet cutting. Non-limiting examples of shaped ceramic abrasive particles include shaped abrasive particles such as triangular plates or elongated ceramic rods/filaments. Shaped ceramic abrasive particles are generally uniform or substantially consistent and retain their sintered shape without the use of binders such as organic or inorganic binders that bind smaller abrasive particles into an agglomerate structure, but do not include abrasive particles obtained by crushing or pulverizing processes that produce abrasive particles of random size and shape. In many embodiments, the shaped ceramic abrasive particles comprise a uniform structure or consist essentially of sintered alpha alumina.

Fig. 1 is a perspective view of an abrasive article 10. FIG. 2 is a cross-sectional view of the abrasive article of FIG. 1 taken along section line 2-2. Fig. 1 and 2 show substantially the same components and are discussed simultaneously. As shown in fig. 1 and 2, the abrasive article 10 includes a nonwoven web 12. The nonwoven web 12 includes a first major surface 14 and an opposing second major surface 16. Each of first major surface 14 and second major surface 16 has an irregular or substantially non-planar profile, although in other embodiments either surface may be planar. The nonwoven web 12 includes a fibrous component 18 that includes individual fibers 20. The nonwoven web 12 also includes abrasive particles 22 dispersed in the nonwoven web 12; the binder 24 adheres the abrasive particles to the individual fibers 20.

Although not limited thereto, the fibrous component 18 may be in the range of about 5 wt% to about 40 wt%, about 10 wt% to about 25 wt%, about 10 wt% to about 20 wt%, about 12 wt% to about 15 wt%, less than, equal to, or greater than about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, or 40 wt% of the abrasive article 10. The fibrous component 18 may include a plurality of individual fibers 20 randomly oriented and entangled with respect to one another. The individual fibers 20 are bonded to each other at points of mutual contact. The individual fibers 20 may be staple fibers or continuous fibers. As generally understood, "staple fibers" refers to fibers of discrete length, and "continuous fibers" refers to fibers that may be any suitable fiber or filament, such as synthetic filaments or inorganic fibers, such as steel filaments, glass fibers, basalt fibers. The steel may be stainless steel, carbon steel, or contain a metal such as copper or an alloy such as brass. The individual fibers 20 may range from about 70 wt% to about 100 wt%, about 80 wt% to about 90 wt% of the fiber component 18, less than, equal to, or greater than about 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 95 wt%, or 100 wt% of the fiber component 18. In further embodiments, the nonwoven web 12 may be free of fibrous components 18 or individual fibers 20, and may instead comprise a sponge or foam material comprising random or ordered cavities.

Individual staple fibers may have a length in the range of about 35mm to 155mm, 50mm to about 105mm, about 40mm to about 60mm, less than, equal to, or greater than about 35mm, 40mm, 45mm, 50mm, 55mm, 60mm, 65mm, 70mm, 75mm, 76mm, 80mm, 85mm, 90mm, 95mm, 100mm, 102mm, 105mm, 110mm, 115mm, 120mm, 125mm, 130mm, 135mm, 140mm, 145mm, 150mm, or 155 mm. The individual staple fibers may have a crimp index value in the range of about 15% to about 60%, about 25% to about 50%, less than, equal to, or greater than about 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60%. Curl index is a measure of the curl produced; for example, before appreciable crimp is induced in the fiber. The crimp index is expressed as the difference of the fiber length in the extended state minus the fiber length in the relaxed (e.g., shortened) state divided by the fiber length in the extended state. The staple fibers may have a denier in the range of about 15 to about 2000, about 20 to about 100, about 500 to about 700, about 800 to about 1000, about 900 to about 1000, less than, equal to or greater than about 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, A fineness of 2000 denier or linear density.

In some examples, the fiber component 18 may include a blend of staple fibers. For example, the fiber component 18 may include a first plurality of individual staple fibers and a second plurality of individual staple fibers. The first plurality of staple fibers and the second plurality of staple fibers in the blend may differ with respect to at least one of a line density value, a crimp index, or a length. For example, the individual staple fibers of the first plurality of individual fibers may have a linear density in the range of from about 15 denier to about 700 denier, from about 20 denier to about 100 denier, less than, equal to, or greater than about 200 denier, 250 denier, 300 denier, 350 denier, 400 denier, 450 denier, 500 denier, 550 denier, 600 denier, 650 denier, or about 700 denier. The individual staple fibers of the second plurality of individual fibers may have a linear density in the range of about 800 denier to about 2000 denier, about 850 denier to about 1000 denier, less than, equal to, or greater than about 800 denier, 850 denier, 900 denier, 950 denier, 1000 denier, 1050 denier, 1100 denier, 1150 denier, 1200 denier, 1250 denier, 1300 denier, 1350 denier, 1400 denier, 1450 denier, 1500 denier, 1550 denier, 1600 denier, 1650 denier, 1700 denier, 1750 denier, 1800 denier, 1850 denier, 1900 denier, 1950 denier, or 2000 denier. Mixtures of individual staple fibers having different linear densities may be used, for example, to provide abrasive articles that can achieve a desired surface finish when used. The length or crimp index of any of the individual fibers may be in accordance with the values discussed herein.

In the example of an abrasive article including a blend of individual staple fibers, the first plurality of individual staple fibers and the second plurality of individual staple fibers may account for different portions of the fiber component 18. For example, the first plurality of individual fibers 20 may be in a range of about 20 wt% to about 80 wt%, about 30 wt% to about 40 wt%, less than, equal to, or greater than about 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt%, or 80 wt% of the fiber component 18. The second plurality of individual fibers 20 may be in a range of about 20 wt% to about 80 wt%, about 60 wt% to about 70 wt%, less than, equal to, or greater than about 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt%, or 80 wt% of the fiber component 18. Although two pluralities of individual staple fibers are discussed herein, it is within the scope of the present disclosure to include additional pluralities of individual staple fibers, such as a third plurality of individual staple fibers that differ with respect to at least one of the linear density values, crimp indices, and/or lengths of the first and second pluralities of individual fibers 20.

The individual fibers 20 of the nonwoven web 12 may comprise any number of suitable materials. Factors that influence the selection of the material include whether the material is suitably compatible with the adherent binder and abrasive particles 22 while also being processable in combination with other components of the abrasive article 10, and the ability of the material to withstand processing conditions (e.g., temperature) such as those employed during application and curing of the binder. The material of the fibers 20 may also be selected to affect properties of the abrasive article 10, such as flexibility, elasticity, durability or life, abrasiveness, and finishing properties. Examples of fibers 20 that may be suitable include natural fibers, synthetic fibers, and mixtures of natural and/or synthetic fibers. Examples of synthetic fibers include those made from polyester (e.g., polyethylene terephthalate), nylon (e.g., nylon-6, polycaprolactam), polypropylene, acrylonitrile (e.g., acrylic resins), rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, polyester (e.g., polyester terephthalic acid), and vinyl chloride-acrylonitrile copolymer. Examples of suitable natural fibers include cotton, wool, jute, and hemp. Some individual fibers 20 may comprise inorganic materials, steel, glass, or basalt. The steel may be stainless steel, carbon steel, or contain a metal such as copper or an alloy such as brass. The individual fibers 20 may be of natural material or recycled or waste material recovered from, for example, garment cutting, carpet manufacturing, fiber manufacturing, or textile processing. The individual fibers 20 may be homogeneous, or may be a composite material, such as a bicomponent fiber (e.g., a co-spun sheath-core fiber). The individual fibers 20 may be staple fibers that are tensioned and crimped.

In some examples, individual fibers 20 may have a non-circular cross-sectional shape or a blend of individual fibers 20 having circular and non-circular cross-sectional shapes (e.g., triangular, delta-shaped, H-shaped, trilobal, rectangular, square, dog-bone, ribbon, or oval).

The abrasive article 10 contains an abrasive component that includes shaped abrasive particles 22 adhered to individual fibers 20. The shaped abrasive particles 22 may range from about 5 wt% to about 70 wt%, about 40 wt% to about 60 wt%, less than, equal to, or greater than about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, or 70 wt% of the abrasive article 10.

There are many types of useful abrasive particles 22 that may be included in abrasive article 10, including shaped ceramic abrasive particles and conventional abrasive particles. The abrasive component may include only the shaped abrasive particles 22 or conventional abrasive particles. The abrasive component may also include a blend of shaped abrasive particles 22 or conventional abrasive particles. For example, the abrasive component can comprise a blend of about 5 wt% to about 95 wt% shaped abrasive particles 22, about 10 wt% to about 50 wt% shaped abrasive particles 22, less than, equal to, or greater than about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 95 wt% shaped abrasive particles 22, and the remaining percentage of conventional abrasive particles. As another example, the abrasive component can comprise a blend of about 5 wt% to about 95 wt% conventional abrasive particles, about 30 wt% to about 70 wt% conventional abrasive particles, less than, equal to, or greater than about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 95 wt% conventional abrasive particles, and the remaining percentage of shaped abrasive particles.

The abrasive particles 22 may be applied to the fibers as individual abrasive particles (e.g., particles 22 not held together with the binder and applied to the fibers 20) or as agglomerates (e.g., particles 22 held together with the binder and applied to the fibers 20). Some agglomerates may include glass-bonded or resin-bonded particles 22. Agglomerates may include crushed abrasive particles, particles 22.

The shaped abrasive particles 22 include any one or more abrasive particles in which at least a portion of the abrasive particles have a predetermined shape. The predetermined shape may be replicated, for example, from a mold cavity used to form the shaped abrasive particle precursor. In embodiments where the shaped abrasive particles 22 are formed in a mold cavity, the predetermined geometry may substantially replicate the mold cavity used to form the shaped abrasive particles 22. In examples where the shaped abrasive particles 22 are formed by extrusion, the shaped abrasive particles 22 may also replicate the shape of the mold. The shaped abrasive particles 22 may also replicate the shape present in a program, such as a Computer Aided Design (CAD) program, if the shaped abrasive particles 22 or abrasive article 10 are formed by an additive manufacturing process. Shaped abrasive particles 22 are not intended to refer to randomly sized crushed abrasive particles formed, for example, by a mechanical crushing operation.

As an example of shaped abrasive particles 22 having a planar triangular shape, fig. 3A-3B illustrate triangular shaped abrasive particles 22 bounded by a triangular base 30, a triangular top 32, and a plurality of sidewalls 34A, 34B, 34C connecting the base 30 and the top 32. The base 30 has

tips

36A, 36B, 36C with an average radius of curvature of less than 50 microns. Fig. 3C-3D illustrate one face of the shaped abrasive particle 22 to better illustrate the radius of curvature of the apex 36A. Generally, the smaller the radius of curvature, the sharper the sidewall edge will be. In some cases, the base and top of the shaped abrasive particles are substantially parallel, resulting in a prismatic or truncated pyramidal (as shown in fig. 3A-3B) shape, but this is not required. As shown, the

sidewalls

34A, 34B, and 34C are of equal size and form a dihedral angle of about 82 degrees with the base 30. However, it should be understood that other dihedral angles (including 90 degrees) may be used. For example, the dihedral angle between the base and each sidewall may independently range from 45 degrees to 90 degrees, 70 degrees to 90 degrees, or 75 degrees to 85 degrees.

Fig. 4A-4E illustrate examples of shaped abrasive particles 22 having a tetrahedral shape. As shown in fig. 4A through 4E, tetrahedral shaped abrasive particles 22 are shaped as regular tetrahedrons. As shown in FIG. 4A, the tetrahedrally shaped abrasive particle 22A has four faces (42A, 44A, 46A, and 48A) joined by six sides (50A, 52A, 54A, 56A, 58A, and 60A) terminating in four peaks (62A, 64A, 66A, and 68A). Each face contacts the other three faces at the edges. Although a regular tetrahedron (e.g., having six equal sides and four faces) is depicted in fig. 4A, it will be recognized that other shapes are also permissible. For example, the tetrahedrally shaped abrasive particles 22A can be shaped as irregular (e.g., edges having different lengths) tetrahedra.

Referring now to fig. 4B, tetrahedrally shaped abrasive particle 22B has four faces (42B, 44B, 46B, and 48B) joined by six edges (50B, 52B, 54B, 56B, 58B, and 60B) terminating in four vertices (62B, 64B, 66B, and 68B). Each face is concave and contacts the other three faces at respective common edges. Although particles having tetrahedral symmetry (e.g., four axes of cubic symmetry and six planes of symmetry) are depicted in fig. 4B, it will be appreciated that other shapes are also permissible. For example, the tetrahedrally shaped abrasive particles 22B can have one, two, or three concave surfaces, with the remaining surfaces being planar.

Referring now to fig. 4C, a tetrahedrally shaped abrasive particle 22C has four faces (42C, 44C, 46C, and 48C) joined by six edges (50C, 52C, 54C, 56C, 58C, and 60C) terminating in four vertices (62C, 64C, 66C, and 68C). Each face is convex and contacts the other three faces at respective common edges. Although particles having tetrahedral symmetry are depicted in fig. 4C, it will be appreciated that other shapes are also permissible. For example, the tetrahedrally shaped abrasive particles 22C can have one, two, or three convex surfaces, with the remaining surfaces being planar or concave.

Referring now to fig. 4D, tetrahedrally shaped abrasive particle 22D has four faces (42D, 44D, 46D, and 48D) joined by six edges (50D, 52D, 54D, 56D, 58D, and 60D) terminating in four vertices (62D, 64D, 66D, and 68D). Although particles having tetrahedral symmetry are depicted in fig. 4D, it will be appreciated that other shapes are also permissible. For example, the tetrahedrally shaped abrasive particles 22D can have one, two, or three convex surfaces, with the remaining surfaces being planar.

There may be deviations from the depictions in fig. 4A-4D. An example of such tetrahedrally shaped abrasive particles 22E is shown in fig. 4E, which shows tetrahedrally shaped abrasive particles 22E having four faces (40E, 44E, 46E, and 48E) joined by six edges (50E, 52E, 54E, 56E, 58E, and 60E) terminating in four peaks (62E, 64E, 66E, and 68E). Each face contacts the other three faces at respective common edges. Each face, edge and apex has an irregular shape.

Any of the shaped abrasive particles 22 may include any number of shape features. The shape characteristics can help to improve the cutting performance of any of the shaped abrasive particles 22. Examples of suitable shape features include openings, concave surfaces, convex surfaces, grooves, ridges, fracture surfaces, low roundness coefficients, or perimeters that include one or more corner points with sharp tips. A single shaped abrasive particle may include any one or more of these features.

The shaped abrasive particles 22 may be oriented on the individual fibers 20 in any suitable manner. The shaped abrasive particles 22 may be oriented by the application of a magnetic field. Alternatively, the shaped abrasive particles 22 may be oriented by placing them in a mold or screen in which the individual cavities are arranged in a predetermined pattern. The amount of shaped abrasive particles 22 that are oriented can be controlled. For example, at least a portion of the total number of shaped abrasive particles 22 may be oriented such that the peaks are oriented in a direction substantially parallel to a line passing through the first and second

major surfaces

14, 16. A single apex may be perfectly aligned with a line passing through first major surface 14 and second major surface 16, but the apex may also deviate from perfect alignment by within about 1 degree to about 20 degrees, within about 1 degree to about 15 degrees, less than, equal to, or greater than about 1 degree, 2 degrees, 3 degrees, 4 degrees, 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees, 10 degrees, 11 degrees, 12 degrees, 13 degrees, 14 degrees, 15 degrees, 16 degrees, 17 degrees, 18 degrees, 19 degrees, or about 20 degrees.

The total amount of shaped abrasive particles 22 having respective apexes oriented in a direction substantially parallel to a line passing through the first and second

major surfaces

14, 16 can be in a range of about 5% to about 70%, about 5% to about 15%, less than, equal to, or greater than about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, or about 70% by weight of the plurality of shaped abrasive particles.

The shaped abrasive particles 22 may also be oriented on the individual fibers 20 such that at least a portion of the total number of shaped abrasive particles 22 comprise faces oriented in a direction substantially perpendicular to a line passing through the first major surface 14 and the second major surface 16. Additionally, in some embodiments, the shaped abrasive particles 22 are disposed in interstices between two or more individual fibers 20 and are held in place by a resin in contact with one or more of the fibers 20. A single face may be substantially perpendicular to a line passing through first major surface 14 and second major surface 16, but the face may also deviate from perfect alignment by within about 1 degree to about 20 degrees, within about 1 degree to about 15 degrees, less than, equal to, or greater than about 1 degree, 2 degrees, 3 degrees, 4 degrees, 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees, 10 degrees, 11 degrees, 12 degrees, 13 degrees, 14 degrees, 15 degrees, 16 degrees, 17 degrees, 18 degrees, 19 degrees, or about 20 degrees.

The total amount of shaped abrasive particles 22 having respective faces oriented in a direction substantially perpendicular to a line through first major surface 14 and second major surface 16 can be in a range from about 5% to about 70%, about 5% to about 15%, less than, equal to, or greater than about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, or about 70% by weight of the plurality of shaped abrasive particles.

The shaped abrasive particles 22 may be distributed throughout the thickness of the abrasive article 10. The thickness of the abrasive article 10 is defined from the first major surface 14 to the second major surface 16. In embodiments in which either or both of first major surface 14 and second major surface 16 have a non-planar or irregular surface, the thickness is measured by the maximum distance between first major surface 14 and second major surface 16. The shaped abrasive particles 22 not located at the first major surface 14 can be located anywhere in the range from about 5% to about 100%, about 20% to about 80%, or less than, equal to, or greater than about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or about 100% of the thickness of the web 102. The portion of the shaped abrasive particles 22 not located at the first major surface 14 may be in a range of about 10 wt% to about 100 wt%, about 50 wt% to about 100 wt%, or less than, equal to, or greater than about 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 95 wt%, or about 100 wt% of the shaped abrasive particles 22.

The shaped abrasive particles 22 may be uniformly or non-uniformly distributed throughout the thickness of the abrasive article 10. Surprisingly, the inclusion of the heat-activated water-forming inorganic component can help provide control over the location of the shaped abrasive particles 22 in the nonwoven web 12, and can help to de-agglomerate the shaped abrasive particles 22 significantly to help orient the particles. In embodiments of the abrasive article 10 in which the shaped abrasive particles 22 are non-uniformly distributed, the shaped abrasive particles 22 may be distributed in multiple regions. Each region may comprise a percentage of the thickness of the abrasive article 10. For example, each region may comprise from 1% to about 50%, from about 10% to about 33%, less than, equal to, or greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, or about 50% of the total thickness of the abrasive article 10. Each region may contain any suitable weight percent of shaped abrasive particles 22. For example, each region may comprise about 5 wt% to about 80 wt%, about 33 wt% to about 50 wt%, less than, equal to, or greater than about 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, 10 wt%, 11 wt%, 12 wt%, 13 wt%, 14 wt%, 15 wt%, 16 wt%, 17 wt%, 18 wt%, 19 wt%, 20 wt%, 21 wt%, 22 wt%, 23 wt%, 24 wt%, 25 wt%, 26 wt%, 27 wt%, 28 wt%, 29 wt%, 30 wt%, 31 wt%, 32 wt%, 33 wt%, 34 wt%, 35 wt%, 36 wt%, 37 wt%, 38 wt%, 39 wt%, 40 wt%, 41 wt%, 42 wt%, 43 wt%, 44 wt%, 45 wt%, 46 wt%, 47 wt%, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, or about 80 wt% of shaped abrasive particles 22. Each region may contain the same weight percent of shaped abrasive particles 22. Alternatively, each region may independently have a different weight percent of shaped abrasive particles 22. The abrasive article 10 may include any number of regions. For example, the abrasive article 10 may include 2, 3, 4, or 5 regions.

The abrasive article 10 may also include conventional (e.g., crushed) abrasive particles. Examples of useful abrasive particles include any abrasive particles known in the abrasive art. Examples of useful abrasive particles include fused aluminum oxide based materials such as aluminum oxide, ceramic aluminum oxide (which may include one or more metal oxide modifiers and/or seeding or nucleating agents) and heat treated aluminum oxide, silicon carbide, co-fused alumina-zirconia, diamond, ceria, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, emery, sol-gel process produced abrasive particles, and mixtures thereof.

Conventional abrasive particles can, for example, have a diameter in the range of about 10 μm to about 2000 μm, about 20 μm to about 1300 μm, about 50 μm to about 1000 μm, less than, equal to, or greater than about 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 100 μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, 450 μm, 500 μm, 550 μm, 600 μm, 650 μm, 700 μm, 750 μm, 800 μm, 850 μm, 900 μm, 950 μm, 1000 μm, 1050 μm, 1100 μm, 1150 μm, 1200 μm, 1250 μm, 1300 μm, 1350 μm, 1400 μm, 1450 μm, 1500 μm, 1550 μm, 1650 μm, 1700 μm, 1750 μm, 1800 μm, 1850 μm, 1900 μm, 1950 μm, or 2000 μm. For example, conventional abrasive particles may have an abrasives industry specified nominal grade. Such abrasive industry recognized grade standards include those known as the American National Standards Institute (ANSI) standard, the european union of abrasive products manufacturers (FEPA) standard, and the japanese industrial standard (HS). Exemplary ANSI grade designations (e.g., specified nominal grades) include: ANSI 12(1842 μm), ANSI 16(1320 μm), ANSI 20(905 μm), ANSI 24(728 μm), ANSI 36(530 μm), ANSI 40(420 μm), ANSI 50(351 μm), ANSI 60(264 μm), ANSI 80(195 μm), ANSI 100(141 μm), ANSI 120(116 μm), ANSI 150(93 μm), ANSI 180(78 μm), ANSI 220(66 μm), ANSI 240(53 μm), ANSI 280(44 μm), ANSI 320(46 μm), ANSI 360(30 μm), ANSI 400(24 μm), and ANSI 600(16 μm). Exemplary FEPA grade designations include P12(1746 μm), P16(1320 μm), P20(984 μm), P24(728 μm), P30(630 μm), P36 (530 μm), P40(420 μm), P50(326 μm), P60(264 μm), P80(195 μm), P100(156 μm), P120(127 μm), P150(97 μm), P180(78 μm), P220(66 μm), P240(60 μm), P280(53 μm), P320(46 μm), P360(41 μm), P400(36 μm), P500(30 μm), P600(26 μm), and P800(22 μm). The approximate average particle size for each grade is listed in parentheses after the name of each grade.

The shaped abrasive particles 22 or crushed abrasive particles can comprise any suitable material or mixture of materials. For example, the shaped abrasive particles 22 may comprise a material selected from the group consisting of alpha-alumina, fused aluminum oxide, heat treated aluminum oxide, ceramic aluminum oxide, sintered aluminum oxide, silicon carbide, titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, fused alumina-zirconia, sol-gel prepared abrasive particles, ceria, zirconia, titania, and combinations thereof. In some embodiments, the shaped abrasive particles 22 and the crushed abrasive particles may comprise the same material. In further embodiments, the shaped abrasive particles 22 and the crushed abrasive particles may comprise different materials.

Filler particles may also be included in the abrasive article 10. Examples of useful fillers include metal carbonates (such as calcium carbonate, calcium magnesium carbonate, sodium carbonate, magnesium carbonate), silicas (such as quartz, glass beads, glass bubbles, and glass fibers), silicates (such as talc, clay, montmorillonite, feldspar, mica, calcium silicate, calcium metasilicate, sodium silicoaluminate, sodium silicate), metal sulfates (such as calcium sulfate, barium sulfate, sodium aluminum sulfate, aluminum sulfate), gypsum, vermiculite, sugar, wood flour, hydrated aluminum compounds, carbon black, metal oxides (such as calcium oxide, aluminum oxide, tin oxide, titanium dioxide), metal sulfites (such as calcium sulfite), thermoplastic particles (such as polycarbonates, polyetherimides, polyesters, polyethylene, poly (vinyl chloride), polysulfone, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, polyethylene, polypropylene, polyethylene, polypropylene, polyethylene, acetal polymers, polyurethane, nylon particles) and thermoset particles (such as phenolic bubbles, phenolic beads, polyurethane foam particles, and the like). The filler may also be a salt, such as a halide salt. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, magnesium chloride. Examples of metal fillers include tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Other miscellaneous fillers include sulfur, organic sulfur compounds, graphite, lithium stearate, and metal sulfides. In some embodiments, individual shaped abrasive particles 22 or individual crushed abrasive particles may be at least partially coated with an amorphous, ceramic, or organic coating. Examples of suitable components of the coating include silanes, glass, iron oxide, aluminum oxide, or combinations thereof. Coatings such as these can aid processability and bonding of the particles to the binder resin.

Abrasive article 10 may also include a thermally activated water-forming inorganic component. The heat activated water forms an inorganic component that may be dispersed in the nonwoven web 12. The heat-activated, water-formed inorganic component may be in a range of about 1 wt% to about 20 wt%, about 3 wt% to about 10 wt%, less than, equal to, or greater than about 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, 4.5 wt%, 5 wt%, 5.5 wt%, 6 wt%, 6.5 wt%, 7 wt%, 7.5 wt%, 8 wt%, 8.5 wt%, 9 wt%, 9.5 wt%, 10 wt%, 10.5 wt%, 11 wt%, 11.5 wt%, 12 wt%, 12.5 wt%, 13 wt%, 13.5 wt%, 14 wt%, 14.5 wt%, 15 wt%, 15.5 wt%, 16 wt%, 16.5 wt%, 17 wt%, 17.5 wt%, 18 wt%, 18.5 wt%, 19 wt%, 19.5 wt%, or about 20 wt% of abrasive article 10. The endothermically activated water-forming inorganic components may be characterized by their ability to dehydrate (e.g., release water) upon exposure to high temperatures. The release of water may be used to cool the abrasive article 10 during use.

The elevated temperature may correspond to the activation temperature of the thermally activated water-forming inorganic component. The activation temperature can be about 300 ℃ or less, about 250 ℃ or less, about 200 ℃ or less, about 100 ℃ or less, in the range of about 200 ℃ to about 300 ℃, about 200 ℃ to about 250 ℃, less than, equal to, or greater than about 50 ℃, 60 ℃, 70 ℃, 80 ℃,90 ℃, 100 ℃, 110 ℃, 120 ℃, 130 ℃, 140 ℃, 150 ℃, 160 ℃, 170 ℃, 180 ℃, 190 ℃, or about 200 ℃.

The thermally activated water-forming inorganic component may comprise any suitable material or mixture of materials. For example, the thermally activated water-forming inorganic component may include a metal hydroxide. The metal of the metal hydroxide may include aluminum, beryllium, cobalt, copper, curium, gold, iron, mercury, nickel, tin, gallium, lead, thallium, zinc, zirconium, calcium, potassium, magnesium, lithium, sodium, alloys thereof, or mixtures thereof. Specific examples of the metal hydroxide include lithium hydroxide, sodium hydroxide, potassium hydroxide, aluminum hydroxide, beryllium hydroxide, cobalt (II) hydroxide, copper (II) hydroxide, cadmium hydroxide, gold (III) hydroxide, iron (II) hydroxide, mercury (II) hydroxide, nickel (II) hydroxide, tin (II) hydroxide, zinc hydroxide, zirconium (IV) hydroxide, or a mixture thereof. An example of a specific aluminum hydroxide is a hydrated aluminum compound.

Any of the metal hydroxides may be surface modified. For example, any metal hydroxide may be surface modified with amines, alkyl groups, epoxy groups, vinyl groups, phenyl groups, or mixtures thereof. Any of these groups may be grafted onto the metal hydroxide. These groups may range from about 1 wt% to about 20 wt%, about 5 wt% to about 10 wt% of the metal hydroxide, less than, equal to, or greater than about 1 wt%, 2 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, 10 wt%, 11 wt%, 12 wt%, 13 wt%, 14 wt%, 15 wt%, 16 wt%, 17 wt%, 18 wt%, 19 wt%, or about 20 wt% of the metal hydroxide.

It has been surprisingly found that the inclusion of a thermally activated water-forming inorganic component, such as a hydrated aluminum compound with shaped abrasive particles 22, improves the grinding performance of the abrasive article. For example, abrasive articles comprising hydrated aluminum compounds have been found to increase the grinding performance of abrasive articles used to abrade carbon steel. In addition, it has been surprisingly found that an abrasive article comprising an aluminum hydrate compound has a higher percentage of shaped abrasive particles 22 having tips oriented in a vertical position (e.g., substantially parallel to a line extending through the first and second major surfaces 12, 14) than a corresponding abrasive article that differs only in the absence of the aluminum hydrate. In addition, it has been surprisingly found that an abrasive article comprising an aluminum hydrate compound has a deeper percentage of shaped abrasive particles 22 that are able to penetrate the abrasive article 10 to the thickness of the abrasive article 10 than a corresponding abrasive article that differs only in that it does not contain aluminum hydrate. In addition, it has been surprisingly found that abrasive articles comprising hydrated aluminum compounds have shaped abrasive particles uniformly distributed in the abrasive article 10. It has also been surprisingly found that inclusion of an aluminum hydrate compound alone or with crushed abrasive particles does not produce abrasive articles that perform as well as those comprising shaped abrasive particles 22 and an aluminum hydrate compound.

In some embodiments, the abrasive article 10 may include a flexible backing in contact with the first major surface 12 or the second major surface 14. A flexible backing may be used to impart strength to the abrasive article 10. A flexible backing may also be used to attach a logo or other visual media to abrasive article 10. Examples of suitable flexible backings include polymeric films, metal foils, woven fabrics, knitted fabrics, paper, vulcanized fibers, staple fibers, continuous fibers, nonwovens, foams, screens, laminates, and combinations thereof.

The abrasive article 10 may be prepared by forming a nonwoven web and applying an adhesive to the fibrous component 18. A make coat may be applied to the nonwoven web 12. The nonwoven web 12 may be rolled to substantially lay down at least some of the flat fibers 20 protruding from the web 12. The abrasive particles 22 may be applied to a make layer to form the nonwoven abrasive web 12. The make layer is cured and an optional size layer may be applied over the make layer, which is subsequently cured to form the abrasive article 10.

In some embodiments, a scrim or reinforcing layer may be attached to the nonwoven abrasive web 12. The scrim may comprise any suitable material, such as a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, a nonwoven, a foam, a screen, a laminate, or combinations thereof. The scrim may be attached to the nonwoven web 12 by needle stitching, needle punching, or by adhesive.

The nonwoven web 12 may be manufactured, for example, by conventional air-laying, carding, stitch-bonding, spunbonding, wet-laying, and/or meltblowing processes. Airlaid nonwoven webs can be prepared using a web forming Machine such as that commercially available from RANDO Machine Company of macrodon, n.y, ma, ny, usa under the trade designation "RANDO WEBBER". The web may also be perforated. In some examples, perforating the web may include needling the web.

The nonwoven abrasive web is prepared by adhering abrasive particles 22 to the nonwoven web 12 with a curable second binder. The binder that may be used to adhere the abrasive particles 22 to the nonwoven web 12 may be selected according to the end product requirements. Examples of binders include those comprising urethane resins, phenolic resins, acrylate resins, and blends of phenolic resins, urea-formaldehyde, latexes, epoxy-phenolic, epoxy resins, and acrylate resins. The amount of coating of abrasive particles 22 may depend on, for example, the particular binder used, the method used to apply abrasive particles 22 (e.g., spray coating), and the size of abrasive particles 22. For example, the coating of the abrasive particles 22 on the nonwoven web 12 may be 100 grams per square meter (g/m)²) To about 5000g/m²About 1500g/m²To about 5000g/m²About 2000g/m²To about 4000g/m²Less than, equal to or greater than about 100g/m²、200g/m²、300g/m²、400g/m²、500g/m²、600g/m²、700g/m²、800g/m²、900g/m²、1000g/m²、1100g/m²、1200g/m²、1300g/m²、1400g/m²、1500g/m²、1600g/m²、1700g/m²、1800g/m²、1900g/m²、2000g/m²、2100g/m²、2200g/m²、2300g/m²、2400g/m²、2500g/m²、2600g/m²、2700g/m²、2800g/m²、2900g/m²、3000g/m²、3100g/m²、3200g/m²、3300g/m²、3400g/m²、3500g/m²、3600g/m²、3700g/m²、3800g/m²、3900g/m²、4000g/m²、4100g/m²、4200g/m²、4300g/m²、4400g/m²、4500g/m²、4600g/m²、4700g/m²、4800g/m²、4900g/m²Or 5000g/m². The abrasive particles 12 may be coated on either or both of the first and second major surfaces of the nonwoven web 12. The abrasive particles 22 may be coated to achieve a substantially uniform distribution of the shaped abrasive particles 22 throughout the web 12.

Additionally, components such as heat activated water-formed inorganic components may be contacted with the nonwoven web 12. In some embodiments, certain components of the abrasive article 10 may be included in the slurry. For example, the slurry may include shaped abrasive particles 22, thermally activated water-formed inorganic components, the materials of the make and size coats, crushed abrasive particles, or any other component or sub-combination of components. The slurry may be stored and applied directly to the nonwoven web 12.

The abrasive article 10 may be used to remove material from the surface of a workpiece. This may be accomplished by contacting the surface of the abrasive article 10 with a workpiece. The workpieces may be contacted, for example, with a force in the range of about 1 newton to about 40 newtons. The abrasive article 10 can then be moved (e.g., rotated) relative to the workpiece while maintaining pressure between the abrasive article 10 and the surface of the workpiece. While the abrasive article 10 can have many suitable shapes, an example of a suitable shape is a disc. The abrasive article 10 may be adapted to remove many different types of materials. Examples of such materials include carbon steel, stainless steel, aluminum, or polymeric materials such as polymeric surface coatings on workpieces.

It has been surprisingly found that a greater amount of work piece is removed as compared to a corresponding abrasive article that is run at the same speed but differs only in having less or no thermally activated water-formed inorganic component. It has also been surprisingly found that abrasive articles comprising a thermally activated water-forming inorganic component are particularly effective in abrading carbon steel.

Examples

The objects and advantages of the present disclosure are further illustrated by the following non-limiting examples. However, the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this disclosure.

The following unit abbreviations are used to describe the examples:

DEG C: degree centigrade

cm: centimeter

g/m²: grams per square meter

Inch: 1 inch to 2.54 cm

mm: millimeter

Unless otherwise indicated, all reagents were obtained or purchased from chemical suppliers such as Sigma Aldrich Company of st. All ratios and percentages are by weight unless otherwise reported.

In the examples that follow, the materials are as follows:

grinding performance

Example 1

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web is further needled into a flexible backing SCR in a knitting machine, rolled, and will haveA prebond coating of the composition shown in Table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. The abrasive coated web was then cured in an oven. Table 1:

table 1: compositions of examples 1 to 9

Example 2

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven.

Example 3

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. In 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. The abrasive coated web was then cured in an oven.

Example 4

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Example 5

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. FIL in the form of PAF was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Example 6

Use the deviceA device such as that commercially available from Raudo machines corporation of Martensin, N.Y., under the trade designation "RANDO WEBBER" is provided having a weight of about 314g/m²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. FIL in WC form was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Example 7

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. FIL in the form of CC was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Example 8

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and the web having the composition shown in table 1The prebond coating was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. Mixing KBF₄FIL in form was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Example 9

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 1 was applied to a prebonded airlaid web. Will K₂B₁₀O₁₆FIL in form was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Table 2: compositions of examples 10 to 14

Example 10

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web is further needled into a flexible backing SCR in a knitting machine, rolled, andand a prebond coating having the composition shown in table 2 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition shown in table 2 was applied to a prebonded airlaid web. The abrasive coated web was then cured in an oven.

Example 11

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 2 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition shown in table 2 was applied to a prebonded airlaid web. FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven.

Example 12

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 2 was applied to a prebonded airlaid web. FIL in the form of alumina was added to the slurry spray at 6.2 wt%. The abrasive coating is then cured in an ovenA cover web. The abrasive coated web was then cured in an oven.

Example 13

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 2 was applied to a prebonded airlaid web. FIL in the boehmite form was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Example 14

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 1 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles having the composition shown in table 2 was applied to a prebonded airlaid web. FIL in the form of MDH1 was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven. The abrasive coated web was then cured in an oven.

Test method

Free hand

3' diameter disks with Roloc^TMAn accessory. By usingCoated abrasive belts corresponding to any of examples 1 to 12 on a back frame ground carbon steel test panels as well as aluminum test panels to apply linear grains on the test pieces. The average Ra on carbon steel was 75 μ in and on aluminum test panels was 150 μ in. The panels and pans were then weighed before testing.

Hand-off short test

For one minute working in the direction of the grains of the respective panel, the scratches in half of the panel were removed with the nonwoven disc according to any of embodiments 1 to 12. For the second one minute period of operation in the direction of the die, the scratches in the second half of the panel are removed. The pan and workpiece were then cleaned and weighed. The Ra of the panel was also measured in 5 discrete areas and recorded.

Hands-free length test

For one minute working in the direction of the grains of the respective panel, the scratches in half of the panel were removed with the nonwoven disc according to any of embodiments 1 to 12. For the second one minute period of operation in the direction of the die, the scratches in the second half of the panel are removed.

The panels were weighed before and after a 2 minute period to determine the mass loss of the panels.

The new panel was used for an additional 2 minutes as used above.

This process was continued for 4 panels with a total hands-free grinding time of 8 minutes per disc. The surface finish of 5 discrete areas of each panel was measured on the first panel and the fourth panel. The highest and lowest surface finish values were discarded and the middle 3 Ra values were averaged. The average surface finishes of panel 1 and panel 4 were averaged to obtain the final surface finish values reported below.

XY automatic test

3' diameter disks with Roloc^TMAn accessory. The discs were subjected to XY testing for 8 cycles. Each cycle was 1 minute long with flat test panels ground with a disc. During testing, the robotic arm is moved in the X and Y directions to abrade the surfaceThe surface of the plate. In 5 discrete areas, the remaining Ra of the disc was checked after the first cycle and after cycle # 8. The panels and pans were weighed before cycle 1 and after cycle 8 to determine the mass loss of the substrates and pans.

The force and RPM used when grinding carbon steel was 5 pounds and 9000RPM or 10 pounds and 11,000 RPM.

The forces used to grind the aluminum were 5 pounds and 9,000RPM or 5 pounds and 11,0000 RPM.

Table 4: test results run on aluminum substrates

Abrasive article construction

Table 5: compositions of examples 15 to 17

Example 15

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 5 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition shown in table 5 was applied to a prebonded airlaid web. The abrasive coated web was then cured in an oven.

Example 16

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 5 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition shown in table 5 was applied to a prebonded airlaid web. FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. The abrasive coated web was then cured in an oven.

Example 17

Using equipment such as that commercially available from Raudo machines corporation of Martensin, N.Y., USA under the trade designation "RANDO WEBBER", a weight of about 314g/m was formed²A lofty, random airlaid web of F1 fibers. The web was further needled into a flexible backing SCR in a knitting machine, rolled, and a prebond coating having the composition shown in table 5 was applied to the airlaid fabric to achieve 355g/m²Dry additional weight of (a). The prebond is then cured in an oven. At 1252.9g/m²Dry add-on weight a slurry coating containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition shown in table 5 was applied to a prebonded airlaid web. FIL in the form of ATH1 was added to the slurry spray at 17.6 wt%. The abrasive coated web was then cured in an oven.

Table 6: test results run on carbon Steel

Table 7: test results run on aluminum

Test method

PSG orientation

Orientation maps of the PSG particles of examples 15, 16 and 17 were generated. The orientation graph uses the directional cosines of the short/minimum axis (PSG width) and the long/maximum axis (PSG length). The Y component of the minimum axis of each PSG is plotted against the Z component of the maximum axis. Each point in the graph is an individual PSG object (i.e., a single PSG, a PSG cluster, a PSG + crush cluster), and N ═ is shown for each graph, where N is the number of PSG objects measured in the scanned dataset. The coordinates (0,0) on the figure refer to the PSG object with a perfectly vertical orientation (preferred orientation). Coordinates (90,90) or (-90 ) refer to a PSG object with a flat orientation (non-preferred orientation). Values between 0 and 90 on the maximum Z-axis indicate the angle of the direction cosine relative to the vector perpendicular to the sample scrim/plane. From the graph, it is possible to determine the grain% for the vertical position (PSG at <15 ° angle to the vertical sample plane) and determine the grain% for the flat orientation.

PSG infiltration

The depth of penetration of the PSG in the nonwoven web was determined using X-ray microtomography analysis. To perform this process, strips of material were cut from each of the abrasive articles of examples 15, 16, and 17. Each embodiment was scanned at 6.00um resolution using a Skyscan 2211 (Bruker MicroCT, Kontich, Belgium) X-ray microtomography scanner, Conteh Belgium, Belgium.) data was collected using an X-ray source setup of 70kV and 110uA, with the energy distribution of the incident beam modified by applying a 0.5mm aluminum filter, projection images were recorded at discrete sample rotation angles using a flat panel detector as the sample was rotated through a 360 degree angular range using an angular step size of 0.10 degrees, averaging five separate detector frames per collected projection image.

The resulting reconstructed image is post-processed to isolate the position of the shaped grains within the scanned sample. The gray threshold allows the abrasive grains to be separated from the higher and lower density materials in the nonwoven construction. The initial process of reconstructing the data set was performed using the computer program CT Analyzer (version 1.16.4, bruke micct, belgium).

Subsequent size filtering of the threshold image removes small non-shaped abrasive grains from the image. The thresholded and size filtered images are analyzed to determine the size, shape and location of the shaped abrasive grains within the data set (X, Y and centroid coordinates at Z). The thresholded and size filtered image is then saved as a separate data set for subsequent inspection of the formed grain orientation. The reconstructed data was further processed using computer software Avizo (version 9.5.0, thermo fisher Scientific, Hillsboro, Oregon, usa) and used for molded grain analysis.

The physical location of each shaped abrasive grain in the data set is identified and the minor and major axes of each shaped grain are evaluated. The cosine of the direction perpendicular to the minor and major axes is calculated and tabulated.

The thresholded image is re-sliced along the XZ plane to obtain a depth profile image of the dataset using CT Analyzer. The abrasive grain area of each depth profile image was determined using Avizo.

Results

The results of the orientation analysis are shown in table 8.

Table 8: PSG orientation

Examples	PSG% in vertical orientation	PSG in Flat orientation%
			15	10.0	6.1
16	8.0	5.6
			17	11.6	4.2

Fig. 5 to 7 show that the PSG particles are distributed in the total depth of the nonwoven web. Furthermore, the PSGs are distributed in a plurality of areas. That is, there are one or more regions along the depth of the nonwoven web that have a higher concentration of PSG. The representative regions have substantially the same concentration of PSG or each region has a different concentration. Table 9 shows the concentration of PSG in examples 15-17 across the total thickness of the abrasive article, specifically, table 9 shows the weight% of particles in the region representing the upper third of the total thickness, the region representing the middle third of the total thickness, and the region representing the lower third of the total thickness. Table 10 shows the weight% of particles in the region that is the top half of the total thickness and the region that is the bottom half of the total thickness.

TABLE 9

Watch 10

Although the terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the embodiments of the invention. Thus, it should be understood that although the present disclosure has been specifically disclosed by specific embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of embodiments of this invention.

Additional embodiments：

The present invention provides the following exemplary embodiments, the numbering of which should not be construed as specifying the degree of importance:

embodiment 1 provides an abrasive article comprising:

a nonwoven web comprising

The component of the fibers or filaments is,

a first main surface, and

a second major surface, wherein the thickness of the nonwoven web is defined from the first major surface to the second major surface;

a plurality of shaped abrasive particles dispersed in at least a portion of the nonwoven web; and

a heat-activated water-forming inorganic component dispersed in the nonwoven web.

Embodiment 2 provides the abrasive article of embodiment 1, wherein the first major surface, the second major surface, or both have a substantially non-planar profile.

Embodiment 3 provides the abrasive article of any one of embodiments 1-2, wherein the fiber component is in the range of about 5% to about 40% by weight of the abrasive article.

Embodiment 4 provides the abrasive article of any one of embodiments 1 to 3, wherein the fiber component is in the range of about 10 wt% to about 25 wt% of the abrasive article.

Embodiment 5 provides the abrasive article of any one of embodiments 1 to 4, wherein the fiber component comprises staple fibers.

Embodiment 6 provides the abrasive article of embodiment 5, wherein the staple fibers have a length in the range of about 35mm to about 155 mm.

Embodiment 7 provides the abrasive article of any one of embodiments 5 or 6, wherein the staple fibers have a length in a range from about 40mm to about 60 mm.

Embodiment 8 provides the abrasive article of any one of embodiments 5 to 7, wherein the staple fibers have a linear density in the range of about 15 denier to about 600 denier.

Embodiment 9 provides the abrasive article of any one of embodiments 5 to 8, wherein the staple fibers have a linear density in the range of about 20 denier to about 100 denier.

Embodiment 10 provides the abrasive article of any one of embodiments 5 to 9, wherein the staple fibers have a curl index value in the range of about 25% to about 40%.

Embodiment 11 provides the abrasive article of any one of embodiments 1 to 10, wherein the fibers are entangled with each other.

Embodiment 12 provides an abrasive article according to any one of embodiments 1 to 11, wherein the fibers are randomly oriented and bonded together at points of mutual contact.

Embodiment 13 provides the abrasive article of any one of embodiments 1 to 12, wherein the fibers comprise a material selected from the group consisting of polyester, nylon, polypropylene, acrylic, rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, vinyl chloride-acrylonitrile copolymer, polyester, and combinations thereof.

Embodiment 14 provides the abrasive article of embodiment 13, wherein the nylon is nylon-6, 6.

Embodiment 15 provides the abrasive article of any one of embodiments 1 to 14, wherein the abrasive particles are in the range of about 2 wt% to about 70 wt% of the abrasive article.

Embodiment 16 provides the abrasive article of any one of embodiments 1 to 15, wherein the abrasive particles are in the range of about 5 wt% to about 50 wt% of the abrasive article.

Embodiment 17 provides the abrasive article of any one of embodiments 1 to 16, wherein the shaped abrasive particles are shaped ceramic abrasive particles.

Embodiment 18 provides the abrasive article of any one of embodiments 1 to 17, wherein at least one of the shaped abrasive particles of the plurality of shaped abrasive particles is tetrahedral and comprises four faces joined by six sides terminating in four vertices, each of the four faces contacting three of the four faces.

Embodiment 19 provides the abrasive article of embodiment 18, wherein at least one of the four faces is substantially planar.

Embodiment 20 provides the abrasive article of any one of embodiments 18 or 19, wherein at least one of the four faces is concave.

Embodiment 21 provides the abrasive article of embodiment 20, wherein the four faces are concave.

Embodiment 22 provides the abrasive article of any one of embodiments 18 to 21, wherein at least one of the four faces is convex.

Embodiment 23 provides the abrasive article of embodiment 22, wherein the four faces are convex.

Embodiment 24 provides the abrasive article of any one of embodiments 18 to 23, wherein at least one of the tetrahedral abrasive particles has edges of equal size.

Embodiment 25 provides the abrasive article of any one of embodiments 18 to 24, wherein at least one of the tetrahedral abrasive particles has edges of different sizes.

Embodiment 26 provides the abrasive article of any one of embodiments 1 to 25, wherein at least one of the shaped abrasive particles in the plurality of shaped abrasive particles comprises a first side and a second side separated by a thickness of the shaped abrasive particle, the first side comprising a first face having a triangular perimeter and the second side comprising a second face having a triangular perimeter, wherein the thickness of the shaped abrasive particle is equal to or less than a length of a shortest side-related dimension of the particle.

Embodiment 27 provides the abrasive article of embodiment 26, further comprising at least one sidewall connecting the first side and the second side.

Embodiment 28 provides the abrasive article of embodiment 27, wherein the at least one sidewall is a sloped sidewall.

Embodiment 29 provides the abrasive article of any one of embodiments 27 or 28, wherein the draft angle of the sloping sidewall is in the range of about 95 degrees to about 130 degrees.

Embodiment 30 provides the abrasive article of any one of embodiments 26 to 29, wherein the first face and the second face are substantially parallel to each other.

Embodiment 31 provides the abrasive article of any one of embodiments 26 to 29, wherein the first face and the second face are substantially non-parallel to each other.

Embodiment 32 provides the abrasive article of any one of embodiments 26 to 31, wherein at least one of the first face and the second face is substantially planar.

Embodiment 33 provides the abrasive article of any one of embodiments 26 to 32, wherein at least one of the first face and the second face is non-planar.

Embodiment 34 provides the abrasive article of any one of embodiments 1 to 33, wherein at least one of the shaped abrasive particles comprises at least one shape feature comprising: openings, concave surfaces, convex surfaces, grooves, ridges, fracture surfaces, low roundness factor, or a perimeter comprising one or more corner points with sharp tips.

Embodiment 35 provides the abrasive article of any one of embodiments 1 to 34, wherein a portion of the plurality of shaped abrasive particles independently comprise tips oriented in a direction substantially parallel to a line through the first major surface and the second major surface.

Embodiment 36 provides the abrasive article of embodiment 35, wherein the portion of the plurality of shaped abrasive particles is in the range of about 5% to about 70% of the plurality of shaped abrasive particles.

Embodiment 37 provides the abrasive article of any one of embodiments 35 or 36, wherein the portion of the plurality of shaped abrasive particles is in the range of about 5% to about 15% of the plurality of shaped abrasive particles.

Embodiment 38 provides the abrasive article of any one of embodiments 35 to 37, wherein the apex is in a range from about 1 degree to about 20 degrees relative to the line through the first and second major surfaces.

Embodiment 39 provides the abrasive article of any one of embodiments 35 to 38, wherein the apex is in a range from about 1 degree to about 15 degrees relative to the line through the first and second major surfaces.

Embodiment 40 provides the abrasive article of any one of embodiments 1 to 39, wherein a portion of the plurality of shaped abrasive particles independently comprise a face oriented in a direction substantially perpendicular to a line through the first major surface and the second major surface.

Embodiment 41 provides the abrasive article of embodiment 40, wherein the portion of the plurality of shaped abrasive particles is in the range of about 5% to about 70% of the plurality of shaped abrasive particles.

Embodiment 42 provides the abrasive article of any one of embodiments 40 or 41, wherein the portion of the plurality of shaped abrasive particles is in the range of about 5% to about 15% of the plurality of shaped abrasive particles.

Embodiment 43 provides the abrasive article of any one of embodiments 40 to 42, wherein the face is in a range from about 1 degree to about 20 degrees relative to the line through the first major surface and the second major surface.

Embodiment 44 provides the abrasive article of any one of embodiments 40 to 43, wherein the face is in a range from about 1 degree to about 15 degrees relative to the line through the first major surface and the second major surface.

Embodiment 45 provides the abrasive article of any one of embodiments 1 to 44, wherein the shaped abrasive particles are distributed in up to about 100% of the thickness of the nonwoven web.

Embodiment 46 provides an abrasive article according to any one of embodiments 1 to 45, wherein the shaped abrasive particles are distributed across the thickness of the nonwoven web in a plurality of regions.

Embodiment 47 provides the abrasive article of embodiment 46, wherein the regions comprise substantially the same weight percent of shaped abrasive particles.

Embodiment 48 provides the abrasive article of any one of embodiments 46 or 47, wherein the nonwoven web comprises two regions of the shaped abrasive particles passing through the thickness of the nonwoven web.

Embodiment 49 provides an abrasive article according to any one of embodiments 46 to 48, wherein the nonwoven web comprises three regions of the shaped abrasive particles passing through the thickness of the nonwoven web.

Embodiment 50 provides the abrasive article of any one of embodiments 46 to 49, wherein each zone of the plurality of zones extends within a range of about 10% to about 50% of the thickness of the nonwoven web.

Embodiment 51 provides the abrasive article of any one of embodiments 46 to 50, wherein each region of the plurality of regions extends within a range of about 33% to about 50% of the thickness of the nonwoven web.

Embodiment 52 provides the abrasive article of any one of embodiments 1 to 51, wherein the shaped abrasive particles comprise a material selected from the group consisting of alpha-alumina, fused aluminum oxide, heat treated aluminum oxide, ceramic aluminum oxide, sintered aluminum oxide, silicon carbide, titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, fused alumina-zirconia, sol-gel prepared abrasive particles, ceria, zirconia, titania, and combinations thereof.

Embodiment 53 provides the abrasive article of any one of embodiments 1 to 52, wherein the shaped abrasive particles are silicon carbide.

Embodiment 54 provides the abrasive article of any one of embodiments 1 to 53, wherein the plurality of shaped abrasive particles are at least one of individual abrasive particles and agglomerates of abrasive particles.

Embodiment 55 provides the abrasive article of any one of embodiments 1 to 54, further comprising a plurality of crushed abrasive particles.

Embodiment 56 provides the abrasive article of any one of embodiments 1 to 55, wherein the abrasive article is a disc.

Embodiment 57 provides the abrasive article of any one of embodiments 1 to 56, further comprising a binder dispersed in the nonwoven web.

Embodiment 58 provides the abrasive article of embodiment 57, wherein the binder is selected from the group consisting of polyurethane resins, polyurethane urea resins, epoxy resins, urea-formaldehyde resins, phenol-formaldehyde resins, and combinations thereof.

Embodiment 59 provides the abrasive article of any one of embodiments 1 to 58, wherein the binder is in the range of about 10 wt% to about 70 wt% of the abrasive article.

Embodiment 60 provides the abrasive article of any one of embodiments 1 to 59, wherein the thermally activated water-forming inorganic component is in a range from about 1 wt% to about 20 wt% of the abrasive article.

Embodiment 61 provides the abrasive article of any one of embodiments 1 to 60, wherein the thermally activated water-forming inorganic component is in a range from about 3 wt% to about 10 wt% of the abrasive article.

Embodiment 62 provides the abrasive article of any one of embodiments 1 to 61, wherein the thermally activated water-forming inorganic component is an endothermically activated water-forming inorganic component having an activation temperature of about 300 ℃ or less.

Embodiment 63 provides the abrasive article of any one of embodiments 1 to 62, wherein the thermally activated water-forming inorganic component is an endothermically activated water-forming inorganic component having an activation temperature in a range of about 200 ℃ to about 300 ℃.

Embodiment 64 provides the abrasive article of any one of embodiments 1 to 63, wherein the thermally activated water-forming inorganic component is an endothermically activated water-forming inorganic component having an activation temperature in a range of about 200 ℃ to about 250 ℃.

Embodiment 65 provides the abrasive article of any one of embodiments 1 to 64, wherein the thermally activated water-forming inorganic component comprises a metal hydroxide.

Embodiment 66 provides the abrasive article of embodiment 65, wherein the metal comprises aluminum, beryllium, cobalt, copper, curium, gold, iron, mercury, nickel, tin, gallium, lead, thallium, zinc, zirconium, calcium, potassium, magnesium, lithium, sodium, alloys thereof, or mixtures thereof.

Embodiment 67 provides the abrasive article of any one of embodiments 65 or 66, wherein the metal is aluminum.

Embodiment 68 provides an abrasive article according to any one of embodiments 65 to 67, wherein the metal hydroxide comprises lithium hydroxide, sodium hydroxide, potassium hydroxide, aluminum hydroxide, beryllium hydroxide, cobalt (II) hydroxide, copper (II) hydroxide, cadmium hydroxide, gold (III) hydroxide, iron (II) hydroxide, mercury (II) hydroxide, nickel (II) hydroxide, tin (II) hydroxide, zinc hydroxide, zirconium (IV) hydroxide, or a mixture thereof.

Embodiment 69 provides the abrasive article of any one of embodiments 65 to 68, wherein the metal hydroxide is aluminum trihydrate.

Embodiment 70 provides the abrasive article of any one of embodiments 65 to 69, wherein at least some of the metal hydroxide components are modified with amines, alkyl groups, epoxy groups, vinyl groups, phenyl groups, or mixtures thereof.

Embodiment 71 provides the abrasive article of any one of embodiments 1 to 70, further comprising a flexible backing in contact with the first major surface or the second major surface.

Embodiment 72 provides the abrasive article of embodiment 71, wherein the flexible backing comprises a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, staple fiber, continuous fiber, nonwoven, foam, screen, laminate, and combinations thereof.

Embodiment 73 provides an abrasive article comprising:

a nonwoven web comprising:

a fiber or filament component;

a first major surface;

a second major surface, wherein a thickness of the nonwoven web is defined between the first major surface and the second major surface;

a plurality of shaped abrasive particles dispersed in the nonwoven web;

an aluminum trihydrate component dispersed in the nonwoven web.

Embodiment 74 provides an abrasive article comprising:

a nonwoven web comprising:

a fiber or filament component;

a first major surface;

a plurality of shaped abrasive particles dispersed in the nonwoven web;

an aluminum hydrate compound dispersed in the nonwoven web,

wherein about 5% to about 70% of the plurality of shaped abrasive particles comprise tips oriented in a direction substantially perpendicular to a line passing through the first major surface and the second major surface.

Embodiment 75 provides an abrasive article comprising:

a nonwoven web comprising:

a fiber or filament component;

a first major surface;

a plurality of shaped abrasive particles dispersed in the nonwoven web, wherein the shaped abrasive particles are distributed in a plurality of distributions throughout the thickness of the nonwoven web;

an aluminum hydrate compound dispersed in the nonwoven web, wherein a portion of the plurality of shaped abrasive particles comprising a face oriented in a direction substantially perpendicular to a line passing through the first major surface and the second major surface is in a range from about 5% to about 70% of the plurality of shaped abrasive particles.

Embodiment 76 provides a slurry comprising:

a plurality of shaped abrasive particles;

a thermally activated water-forming inorganic component; and

a binder;

a lubricant; and

a solvent.

Embodiment 77 provides the slurry of embodiment 76, wherein the shaped abrasive particles are tetrahedral shaped abrasive particles, triangular shaped abrasive particles, or a mixture thereof.

Embodiment 78 provides the slurry of any one of embodiments 76 or 77, wherein the abrasive particles are in the range of about 2% to about 70% by weight of the slurry.

Embodiment 79 provides the slurry of any one of embodiments 76 to 78, wherein the abrasive particles are in the range of about 5% to about 70% by weight of the slurry.

Embodiment 80 provides the slurry of any one of embodiments 76 to 79, wherein the binder is in the range of about 10 wt% to about 70 wt% of the slurry.

Embodiment 81 provides the slurry of any one of embodiments 76-80, wherein the binder is selected from the group consisting of polyurethane resins, polyurethane urea resins, epoxy resins, urea-formaldehyde resins, phenol-formaldehyde resins, and combinations thereof.

Embodiment 82 provides the slurry of any one of embodiments 76 to 81, wherein the thermally activated water-forming inorganic component is in the range of about 1% to about 20% by weight of the slurry.

Embodiment 83 provides the slurry of any of embodiments 76-82, wherein the thermally activated water-forming inorganic component is in a range of about 3 wt% to about 10 wt% of the slurry.

Embodiment 84 provides the slurry of any of embodiments 76-83, wherein the thermally activated water-forming inorganic component is an endothermically activated water-forming inorganic component comprising a reaction temperature of about 300 ℃ or less.

Embodiment 85 provides the slurry of any one of embodiments 76 to 84, wherein the thermally activated water-forming inorganic component is an endothermically activated water-forming inorganic component comprising a reaction temperature in a range of about 200 ℃ to about 300 ℃.

Embodiment 86 provides the slurry of any one of embodiments 76 to 85, wherein the thermally activated water-forming inorganic component is an endothermically activated water-forming inorganic component comprising a reaction temperature in a range of about 200 ℃ to about 250 ℃.

Embodiment 87 provides the slurry of any one of embodiments 76 to 86, wherein the thermally activated water-forming inorganic component comprises a hydrated metal.

Embodiment 88 provides the slurry of embodiment 87, wherein the metal comprises aluminum, calcium, potassium, magnesium, alloys thereof, or mixtures thereof.

Embodiment 89 provides the slurry of any one of embodiments 87 or 88, wherein the metal is aluminum.

Embodiment 90 provides the slurry of any one of embodiments 87 to 89, wherein the metal hydrate is an aluminum hydrate compound.

Embodiment 91 provides a method of making an abrasive article according to any one of embodiments 1 to 90, the method comprising:

forming a nonwoven web of said fibers or filaments;

perforating the web;

applying the abrasive particles and binder to the perforated web; and

curing the binder to provide the abrasive article.

Embodiment 92 provides the method of embodiment 91, wherein the abrasive particles are applied to the first major surface, the second major surface, or both.

Embodiment 93 provides the method of any one of embodiments 91 or 92, wherein the abrasive particles are sprayed on the first major surface, the second major surface, or both.

Embodiment 94 provides the method of any one of embodiments 91 to 93, wherein at about 100g/m²To about 5000g/m²Additional weights in the range apply the abrasive particles to the nonwoven web.

Embodiment 95 provides the method of any one of embodiments 91 to 94, wherein at about 2000g/m²To about 4000g/m²Additional weights in the range apply the abrasive particles to the nonwoven web.

Embodiment 96 provides the method of any one of embodiments 91 through 95, wherein forming the web of fibers comprises air-laying the fibers.

Embodiment 97 provides the method of embodiments 91-96, wherein the fibers are air-laid with a web former.

Embodiment 98 provides a method for removing material from a surface of a workpiece, the method comprising:

contacting the abrasive article of any one of embodiments 1 to 75 or the abrasive article formed according to the method of any one of embodiments 91 to 97 against the workpiece; and

moving the abrasive article relative to the workpiece while maintaining pressure between the abrasive article and the surface of the workpiece to remove material from the surface of the workpiece.

Embodiment 99 provides the method of embodiment 98, wherein the abrasive article is in the shape of a disc having a central axis, and the movement of the abrasive article relative to the workpiece is achieved by rotating the abrasive article about the central axis.

Embodiment 100 provides the method of any one of embodiments 98 or 99, wherein the material removed from the workpiece is carbon steel.

Embodiment 101 provides the method of any of embodiments 98-100, wherein a greater amount of the workpiece is removed than a corresponding abrasive article run at the same speed but differing only in having less or no thermally activated water-formed inorganic component.

Claims

1. An abrasive article, comprising:

a nonwoven web comprising:

the component of the fibers or filaments is,

a first main surface, and

a plurality of individual shaped abrasive particles dispersed in at least a portion of the nonwoven web; and

2. The abrasive article of claim 1, wherein the fibers comprise a material selected from the group consisting of polyester, nylon, polypropylene, acrylic, rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, vinyl chloride-acrylonitrile copolymer, and combinations thereof.

3. The abrasive article of any one of claims 1 or 2, wherein the individual shaped abrasive particles are distributed across the thickness of the nonwoven web in multiple regions.

4. The abrasive article of any one of claims 1 to 3, wherein the individual shaped abrasive particles comprise a material selected from the group consisting of alpha-alumina, fused aluminum oxide, heat treated aluminum oxide, ceramic aluminum oxide, sintered aluminum oxide, silicon carbide, titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, fused alumina-zirconia, sol-gel produced abrasive particles, ceria, zirconia, titania, and combinations thereof.

5. The abrasive article of any one of claims 1 to 4, wherein the thermally activated water-formed inorganic component is in a range from about 1 wt% to about 20 wt% of the abrasive article.

6. The abrasive article of any one of claims 1 to 5, wherein the thermally activated water-formed inorganic component is an endothermically activated water-formed inorganic component having an activation temperature of about 300 ℃ or less.

7. The abrasive article of any one of claims 1 to 6, wherein the thermally activated water-forming inorganic component comprises a metal hydroxide.

8. The abrasive article of claim 7, wherein the metal hydroxide is a hydrated aluminum compound.

9. An abrasive article, comprising:

a nonwoven web comprising:

a fiber or filament component;

a first major surface;

a plurality of individual shaped abrasive particles dispersed in the nonwoven web; and

an aluminum hydrate compound dispersed in the nonwoven web.

10. A method of making the abrasive article of any one of claims 1 to 9, the method comprising:

forming a nonwoven web of said fibers or filaments;

perforating the web;

applying the abrasive particles and binder to the perforated web; and

curing the binder to provide the abrasive article.

11. The method of claim 10 wherein forming the nonwoven web of fibers comprises air-laying the fibers.

12. A method for removing material from a surface of a workpiece, the method comprising:

bringing the abrasive article according to any one of claims 1 to 9 or the abrasive article formed according to the method of any one of claims 10 or 11 into abutting contact with the workpiece; and

13. The method of claim 12, wherein the abrasive article is in the shape of a disc having a central axis, and movement of the abrasive article relative to the workpiece is achieved by rotating the abrasive article about the central axis.

14. The method of any one of claims 12 or 13, wherein the material removed from the workpiece is carbon steel.

15. The method of any of claims 12 to 14, wherein a greater amount of the workpiece is removed than a corresponding abrasive article running at the same speed but differing only in having less or no thermally activated water-formed inorganic component.