KR20220156966A - fixed abrasive buff - Google Patents

Abstract

A system and method comprising providing a fixed abrasive buff having a central hub and a plurality of fabric layers attached to the central hub. The abrasive composition is dispersed throughout the fabric layer and includes a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder. A content of abrasive particles at an outer edge of the plurality of fabric layers is higher than a content of abrasive particles at an inner edge of the plurality of fabric layers.

Description

fixed abrasive buff

Conventional buffs and buffing wheels (collectively "buffs") are used to abrade, among others, components formed from a variety of metals, plastics, and ceramics.

These conventional buffs are generally free of fixed abrasives and are commonly used in so-called buffing processes for polishing or surface finishing components formed of various materials (eg metals, plastics, ceramics, etc.). Instead of including a fixed abrasive, an abrasive buffing emulsion or compound is applied externally to the working surface of a conventional buff and periodically re-applied during the grinding operation. These conventional buffs suffer from a variety of disadvantages, including high maintenance and cleaning costs, waste of a lot of material during buffing, longer buffing times due to repeated reapplication of the abrasive buffing emulsion or compound, and costs and concerns associated with disposal of the abrasive buffing emulsion or compound. have Accordingly, a need continues to exist for improved fixed abrasive buffs that provide improved abrasive processing performance, efficiency, and improved surface quality.

summary

In one aspect, the present invention generally relates to a fixed abrasive buff comprising a central hub, a plurality of fabric layers attached to the central hub, and an abrasive composition disposed throughout or embedded within the plurality of fabric layers. An abrasive composition includes a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder. The content of abrasive particles at the outer edges of the plurality of fabric layers may be higher than the content of abrasive particles at the inner edges of the plurality of fabric layers.

In order that the features and advantages of the embodiments may be achieved and understood in more detail, a more specific description may be made with reference to the embodiments shown in the accompanying drawings. However, the drawings illustrate only some embodiments and, therefore, should not be considered limiting in scope as there may be other equally effective embodiments.
1 is an image of a fixed abrasive buff according to one embodiment of the present invention.
2 is a flow diagram of a method 200 of forming a fixed abrasive buff according to one embodiment of the present invention.
3A is an image of an uncoated buff mounted on a rotary device prior to coating with an abrasive composition according to one embodiment of the present invention.
3B is an image of an uncoated buff immersed in and spinning in an abrasive composition according to one embodiment of the present invention.
3C is an image of a fixed abrasive buff coated with and removed from an abrasive composition according to one embodiment of the present invention.
3D is an image of a fixed abrasive buff coated with an abrasive composition after spinning to remove excess abrasive composition according to one embodiment of the present invention.
4A shows a device having a pressurized air delivery device according to one embodiment of the present invention.
4B shows an image of a pressurized air delivery device according to one embodiment of the present invention.
5A is an image of a control abrasive buff used without an abrasive composition.
5B is an image of a used sample fixing abrasive buff according to one embodiment of the present invention.
6A is an image of a brass panel buffed by a control abrasive buff without an abrasive composition.
6B is an image of a brass panel buffed with a sample fixing abrasive buff in accordance with one embodiment of the present invention.
7 shows a chart providing comparative data of surface finish (Ra) versus time for one embodiment of a control set abrasive buff and a sample set abrasive buff.
8 shows a chart providing comparative data of surface finish (Rz) versus time for one embodiment of a control set abrasive buff and a sample set abrasive buff.
9 shows a chart providing comparative data of cumulative material removal versus time for one embodiment of a control set abrasive buff and a sample set abrasive buff.
10 shows a chart providing comparative data of surface finish (Ra) versus time for one embodiment of a control set abrasive buff and a sample set abrasive buff.
11 shows a chart providing comparative data of surface finish (Rz) versus time for one embodiment of a control set abrasive buff and a sample set abrasive buff.
12 shows a chart providing comparative data of cumulative material removal versus time for one embodiment of a control set abrasive buff and a sample set abrasive buff.
13 shows a chart providing comparative data of power requirements versus time for one embodiment of a control set abrasive buff and a sample set abrasive buff.
14 shows an image of a disassembled sample fixing abrasive buff with the sample strip removed.
The use of the same reference signs in different drawings indicates similar or identical items.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

fixed abrasive buff

1 shows an image of a fixed abrasive buff 100 according to one embodiment of the present invention. The fixed abrasive buff 100 generally includes a central hub 102, a plurality of fabric layers 104 attached to the central hub 102, and an abrasive composition 106 disposed throughout or embedded in the plurality of fabric layers 104. ). The abrasive composition 106 includes a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder. The abrasive composition 106 is generally formed in a plurality of fabric layers (including abrasive particles) such that the abrasive composition 106 (including abrasive particles) penetrates into and between the fibers of each of the plurality of fabric layers 104 of the fixed abrasive buff 100. 104) can be placed throughout or embedded inside.

How to form a fixed abrasive buff

2 shows a flow chart of a method 200 of forming a fixed abrasive buff 100 according to one embodiment of the present invention. Method 200 may begin at block 202 by providing an uncoated buff comprising a central hub 102 and a plurality of fabric layers 104 attached to the central hub 102 . Method 200 may continue at block 204 by at least partially immersing the uncoated buff in an abrasive composition 106 having a polymeric binder and a plurality of abrasive particles. The method 200 may continue at block 206 by rotating the buff within the polishing composition 106 .

The method 200 may continue at block 208 by applying pressure to the plurality of fabric layers 104 causing the plurality of fabric layers 104 to separate or spread apart from each other during the coating process. In some embodiments, spreading of the plurality of fabric layers 104 can be achieved by applying or directing pressurized air radially towards the plurality of fabric layers 104 such that the plurality of fabric layers 104 spread or separate from each other. have. In some embodiments, spreading of the plurality of fabric layers 104 presses the plurality of fabric layers 104 against the sidewall of the container containing the polishing composition 106 such that the plurality of fabric layers 104 spread or separate from each other. can be achieved by doing

In some embodiments, the steps of blocks 206 and 208 coat the plurality of fabric layers 104 with the polishing composition 106 to rotate the buff within the polishing composition 106 to form a fixed abrasive buff 100. while simultaneously applying pressure to the plurality of fabric layers 104 such that the plurality of fabric layers 104 are spread apart or separated from each other. In some embodiments, the buff rotation within the polishing composition 106 to coat the plurality of fabric layers 104 with the polishing composition 106 is performed at an inner edge adjacent the central hub 102 of the plurality of fabric layers 104. A higher concentration, higher content, and/or higher addition or total amount of polishing composition 106 at the outer edge of plurality of fabric layers 104 as compared to the concentration, amount, and/or weight of polishing composition 106 . can cause weight. In some embodiments, method 200 may result in better penetration of abrasive composition 106 into plurality of fabric layers 104 of set abrasive buff 100 .

The method 200 may continue at block 210 by removing the fixed abrasive buff 100 from the polishing composition 106 and rotating the fixed abrasive buff 100 to spin off excess abrasive composition 106. . In some embodiments, the fixed abrasive buff 100 may be completely removed from the abrasive composition 106 and rotated at a controlled speed to facilitate removal of excess abrasive composition. In at least one non-limiting embodiment, the rotational speed may be controlled to facilitate other features of the fixed abrasive buff 100 as described in embodiments herein.

The method 200 may continue at block 212 by curing the polishing composition 106 on the set abrasive buff 100 . In some embodiments, curing the polishing composition 106 may include allowing sufficient time for the polishing composition 106 to cure and/or solidify. In other embodiments, curing the polishing composition 106 may include a process that accelerates drying or induces hardening, such as applying heat (eg, baking) to the fixed abrasive buff 100 . Without wishing to be bound by theory, one or more process steps, including, but not limited to, for example, applying pressure to the plurality of fabric layers 104, may determine a specific distribution of abrasive particles in a given layer, as well as differences in abrasive particle distribution between layers. can facilitate

3A-3D show the various stages of one embodiment in forming a fixed abrasive buff 100 . 3A shows an uncoated buff comprising a central hub 102 and a plurality of fabric layers 104 attached to the central hub 102, according to one embodiment of the present invention. The uncoated buff is mounted to the rotary device via the central hub 102 and suspended over a holding container containing the polishing composition 106. 3B shows a buff that is immersed in an abrasive composition 106 and spun to coat a plurality of fabric layers 104 with the abrasive composition 106 . The plurality of fabric layers 104 are also pressed against the sidewall of the holding vessel containing the abrasive composition 106 such that the plurality of fabric layers 104 are spread apart or separated from each other. However, in other embodiments, the portion of the plurality of fabric layers 104 where the pressurized air rotates outside the polishing composition 106 such that the plurality of fabric layers 104 spread apart or separate from each other as the plurality of fabric layers 104 rotate through the polishing composition 106. can be applied in the radial direction. 3C shows the fixed abrasive buff 100 removed from the polishing composition 106. 3D shows the fixed abrasive buff 100 coated with the polishing composition 106 after spinning the set abrasive buff 100 to remove excess abrasive composition 106. Once cured, the fixed abrasive buff will be ready for use in a buffing process to abrade or surface finish a workpiece.

FIG. 4A applies or directs compressed air to portions of the plurality of fabric layers 104 such that the plurality of fabric layers 104 are spread apart or separated from each other while being rotated by the rotary device 154 through the polishing composition 106. shows a device 150 having a pressurized air delivery device 152. The uncoated buff may be mounted to the rotary device 154 via the central hub 102 and at least partially suspended within the polishing composition 106 . Pressurized air delivery device 152 may be connected to an air compressor or other compressed air delivery device. The pressurized air delivery device 152 directs pressurized air through the plurality of fabric layers 104 rotating out of the polishing composition 106 such that the plurality of fabric layers 104 spread apart or separate from each other as the plurality of fabric layers 104 rotate through the polishing composition 106. may be applied or directed radially to a portion, compared to the concentration, amount and/or weight of the abrasive composition 106 at the inner edge adjacent the central hub 102 of the plurality of fabric layers 104 to the plurality of fabric layers 104; A higher concentration, higher content and/or higher weight of the abrasive composition 106 at the outer edge of the fabric layer 104 may result. 4B shows an image of a pressurized air delivery device 152 according to one embodiment of the present invention. In the embodiment shown, pressurized air delivery device 152 includes a plurality of air delivery holes. However, it will be appreciated that the number of air delivery holes in the pressurized air delivery device 152 may be selected based on the width, diameter, number of fabric layers 104 or other characteristics of the stationary abrasive buff 100 .

Abrasive grain or particle distribution

In some embodiments, the buff rotation within the polishing composition 106 to coat the plurality of fabric layers 104 with the polishing composition 106 is performed at an inner edge adjacent the central hub 102 of the plurality of fabric layers 104. resulting in a higher concentration, higher content and/or higher weight of the polishing composition 106 at the outer edge of the plurality of fabric layers 104 compared to the concentration, amount and/or weight of the polishing composition 106 can do. This may provide advantageous surface finish characteristics because more abrasive particles are disposed on the periphery of the plurality of fabric layers 104 of the fixed abrasive buff 100 where most of the surface finish of the workpiece occurs.

In some embodiments, the content of abrasive particles at the outer edges of the plurality of fabric layers 104 may be higher than the content of abrasive particles at the inner edges adjacent the central hub 102 of the plurality of fabric layers 104 . In some embodiments, the abrasive particle content at the outer edge of the plurality of fabric layers 104 is 10% greater, 15% greater, 20% greater than the abrasive particle content at the inner edge of the plurality of fabric layers 104 , 25% or more, 30% or more, 35% or more, 40% or more, 45% or more or 50% or more. In some embodiments, the abrasive particle content at the outer edge of the plurality of fabric layers 104 is 300% or less, 200% or less, 100% or less than the abrasive particle content at the inner edge of the plurality of fabric layers 104 , 90% or less, 80% or less, 70% or less, 60% or less or 50% or less higher. In addition, the content of abrasive particles at the outer edge of the plurality of fabric layers 104 is between any of these minimum and maximum values, such as 10% or more than the content of abrasive particles at the inner edge of the plurality of fabric layers 104. It will be appreciated that it may be up to 300% higher, or even up to 50% up to 100% higher than the content of abrasive particles at the inner edge of the plurality of fabric layers 104 . For example, in one embodiment, the abrasive particle content at the outer edge can be 0.639 grams and the abrasive particle content at the inner edge can be 0.307 grams. The percentage is calculated using the following formula: (0.639-0.307)/0.639 = 0.52%. Thus, in this embodiment, the content at the outer edge is 52% higher than the content at the inner edge of the plurality of fabric layers 104 .

In some embodiments, the added weight of the polishing composition 104 at the outer edge of the plurality of fabric layers 104 is greater than the polishing composition 104 at the inner edge adjacent the central hub 102 of the plurality of fabric layers 104. may be higher than the added weight of In some embodiments, the added weight of the polishing composition 104 at the outer edge of the plurality of fabric layers is greater than 10%, 15%, or more than the added weight of the polishing composition 104 at the inner edge of the plurality of fabric layers 104. higher than 20%, higher than 25%, higher than 30%, higher than 35%, higher than 40%, higher than 45% or higher than 50%. In some embodiments, the added weight of the polishing composition 104 at the outer edge of the plurality of fabric layers is 300% or less, 200% less than the added weight of the polishing composition 104 at the inner edge of the plurality of fabric layers 104. or less, 100% or less, 90% or less, 80% or less, 70% or less, 60% or less or 50% or less higher. Additionally, the added weight of the polishing composition 104 at the outer edges of the plurality of fabric layers 104 may be between any of these minimum and maximum values, such as the polishing composition 104 at the inner edges of the plurality of fabric layers 104. 10% to 300% higher than the add-on weight of the fabric layer 104, or even 50% to 100% higher than the add-on weight of the abrasive composition 104 at the inner edge of the plurality of fabric layers 104. It will be. For example, in one embodiment, the add weight of the polishing composition 104 at the outer edge can be 1.295 grams and the add weight of the polishing composition 104 at the inner edge can be 0.623 grams. Calculate (1.295-0.623)/1.295 = 0.52%. Thus, in this embodiment, the added weight of the polishing composition 104 at the outer edge is 52% higher than the added weight of the polishing composition 104 at the inner edge.

In some embodiments, the total weight of the set abrasive buff 100 at the outer edge of the plurality of fabric layers 104 is greater than the total weight at the inner edge adjacent the central hub 102 of the plurality of fabric layers 104. can In some embodiments, the total weight of the set abrasive buff 100 at the outer edges of the plurality of fabric layers is 10%, 15%, 20% or more than the total weight at the inner edges of the plurality of fabric layers 104. , 25% or more, 30% or more, 35% or more, 40% or more, 45% or more or 50% or more. In some embodiments, the total weight of the set abrasive buff 100 at the outer edge of the plurality of fabric layers is 300% or less, 200% or less, 100% or less than the total weight at the inner edge of the plurality of fabric layers 104 , 90% or less, 80% or less, 70% or less, 60% or less or 50% or less higher. Further, the total weight 100 of the fixed abrasive buff at the outer edges of the plurality of fabric layers 104 may be between any of these minimum and maximum values, such as the weight of the fixed abrasive buffs at the inner edges of the plurality of fabric layers 104. 10% to 300% higher than the total weight 100, or even 50% to 100% higher than the total weight 100 of the fixed abrasive buff at the inner edge of the plurality of fabric layers 104. It will be understood that there is For example, in one embodiment, the total weight of the polishing composition 104 at the outer edge may be 1.901 grams and the total weight of the polishing composition 104 at the inner edge may be 1.229 grams. Calculate (1.901-1.229)/1.901 = 0.32%. Thus, in this embodiment, the total weight of the polishing composition 104 at the outer edge is 32% higher than the total weight of the polishing composition 104 at the inner edge.

fabric layer

The plurality of fabric layers 104 can generally be made of any number of different materials, including woven fabrics, non-woven fabrics, or combinations thereof. Fabric layer 104 may be formed from a plurality of fibers or yarns, such as natural fibers or yarns, synthetic fibers or yarns, or combinations thereof. Natural fibers or yarns may include one or more types of natural fibers. In some embodiments, the natural fiber or yarn is a cellulosic fiber or yarn, cotton fiber or yarn, flax fiber or yarn, hemp fiber or yarn, jute fiber or yarn, ramie fiber or yarn, sisal fiber or yarn, linen fiber or yarn , silk fibers or yarns or combinations thereof. In certain embodiments, the natural fiber or yarn may consist essentially of cotton fiber or yarn. Synthetic fibers or yarns may include one or more types of synthetic fibers or yarns. In one embodiment, the synthetic fibers or yarns may include glass fibers or yarns, polymeric fibers or yarns, or combinations thereof. In certain embodiments, the polymeric fibers or yarns may include acrylic fibers or yarns, nylon fibers or yarns, olefin fibers or yarns, polyester fibers or yarns, rayon fibers or yarns, modal fibers or yarns, or combinations thereof. In certain embodiments, synthetic fibers consist essentially of polyester fibers. In another specific embodiment, the synthetic fibers consist essentially of nylon fibers.

In some embodiments, plurality of fabric layers 104 may include a woven fabric. A woven fabric may include multiple yarns such as warp and weft. In some embodiments, the abrasive composition may be at least partially disposed within or between yarns, such as between warp and weft yarns. Also, in some embodiments, the abrasive composition may be disposed through the fabric between the yarns from the first side of the fabric to the second side of the fabric.

In some embodiments, plurality of fabric layers 104 include a non-woven fabric. As used herein, the term "nonwoven fabric" refers to a web having a structure of individual fibers that are interlaid and not in an identifiable manner as in a knitted fabric. In certain embodiments, the nonwoven fabric is a spunbond fabric of spunbond fibers (also known as “spunlaid” fabric), a meltblown fabric of meltblown fibers, or a combination thereof. can include In some embodiments, the abrasive composition may be disposed at least partially within or between fibers of the nonwoven web. Also, in some embodiments, the abrasive composition may be disposed between fibers of the web from the first side of the fabric to the second side of the fabric. of non-woven fabric.

number of fabric layers

The fixed abrasive buff 100 is generally formed by a plurality of fabric layers 104 . In some embodiments, the fixed abrasive buff 100 has 2 or more layers, 4 or more layers, 6 or more layers, 8 or more layers, 10 or more layers, 12 or more layers, 15 or more layers, 20 or more layers. layer or more than 25 layers. In some embodiments, the fixed abrasive buff 100 may include no more than 100 layers, no more than 50 layers, no more than 25 layers, no more than 20 layers, no more than 15 layers, or no more than 12 layers. can It will also be appreciated that the fixed abrasive buff 100 may include a plurality of fabric layers 104 between any of these minimum and maximum values, such as at least two layers and no more than 30 layers.

polishing composition

The abrasive composition 106 may generally include a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder. The abrasive composition 106 is generally formed in a plurality of fabric layers (including abrasive particles) such that the abrasive composition 106 (including abrasive particles) penetrates into and between the fibers of each of the plurality of fabric layers 104 of the fixed abrasive buff 100. 104) can be placed throughout or embedded inside. The polishing composition 106 can be applied to the fixed abrasive buff 100 and can include beneficial added weight. In some embodiments, the added weight of the polishing composition 106 is 15 grams or more, 16 grams or more, 17 grams or more, 18 grams or more, 19 grams or more, 20 grams or more, 21 grams or more, 22 grams or more, 23 grams or more, It may be greater than 24 grams or greater than 25 grams.

polymer binder

Polymeric binders can generally be formed from a single polymer or a blend of polymers. In some embodiments, the polymer binder is an epoxy composition, an acrylic composition, a phenolic composition, a polyurethane composition, a phenolic composition, a polysiloxane composition, an acrylic latex composition, a thermoset rubber composition, a thermoset elastomer composition, a styrene butadiene rubber composition, an acrylonitrile-butadiene rubber composition, a polybutadiene composition, or a combination thereof. In some embodiments, the polymeric binder may include a self-crosslinking carboxylated styrene-butadiene composition. In another embodiment, the polymeric binder may include a carboxylated acrylic composition. In some embodiments, the polymeric binder is one or more active filler particles, additives, one or more reactive components or polymeric components, thickeners, solvents, plasticizers, chain transfer agents, catalysts, antifoams, stabilizers, dispersants, curing agents, rheology modifiers, reaction mediators, and agents that affect the fluidity of the dispersion, or any combination thereof. In some embodiments, the polymer binder can be pliable after curing such that the plurality of fabric layers 104 have a “soft” feel, also known as a soft “drape,” when the plurality of fabric layers 104 are touched. It feels soft, flexible, and conformable around the workpiece.

The polymeric binder may include a desirable glass transition temperature (Tg), which may contribute to advantageous abrasive properties. In some embodiments, the polymeric binder may comprise a glass transition temperature of -30°C or higher, -25°C or higher, -20°C or higher, or -15°C or higher. In some embodiments, the polymeric binder is glass at 60°C or less, 50°C or less, 40°C or less, 30°C or less, 20°C or less, 10°C or less, 0°C or less, or -1°C or less. Transition temperature may be included. It will also be appreciated that the polymeric binder may include a glass transition temperature between any of these minimum and maximum values, such as greater than -30°C and less than or equal to 30°C.

The amount of polymeric binder in the polishing composition can vary. In some embodiments, the polishing composition may include at least 10 wt.% polymer binder, at least 15 wt.%, at least 20 wt.%, at least 25 wt.%, at least 35 wt.%, or at least 50 wt.% polymer binder. can In some embodiments, the polishing composition contains up to 80 wt.% polymeric binder, up to 75 wt.%, up to 70 wt.%, up to 65 wt.%, up to 60 wt.%, up to 55 wt.%, up to 50 wt.% or less, 40 wt.% or less, 35 wt.% or less, or 30 wt.% or less of the polymeric binder. It will also be appreciated that the amount of polymeric binder in the polishing composition can be between any of these minimum and maximum values, such as greater than 10 wt.% and less than or equal to 80 wt.% polymeric binder.

abrasive grain

The abrasive particles may include inorganic materials that are essentially single-phase, such as alumina, silicon carbide, silica, ceria, and/or harder, high-performance superabrasive particles, such as cubic boron nitride and diamond. Abrasive particles may also include engineered abrasives that include macrostructures and specific three-dimensional structures. The agglomerates may include abrasive agglomerates and/or non-abrasive agglomerates. In some embodiments, agglomerates may include multiparticulate material, which may be formed via a slurry processing pathway that includes removal of the liquid carrier through volatilization or evaporation, leaving uncalcined ("green") agglomerates; , which is optionally subjected to high temperature treatment (ie calcining, sintering) to form usable calcined agglomerates.

Abrasive particles are silica, alumina (fused or sintered), zirconia, riconia/alumina oxide, zirconium silicate, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide , tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery, or any one or combination of abrasive particles including a combination thereof. For example, abrasive particles and/or agglomerates may be silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, eutectic alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, and blends thereof. In certain embodiments, the abrasive particles consist essentially of silicon carbide.

The average particle size of the abrasive particles can vary. The grain size of an abrasive grain is generally specified as the longest dimension of the abrasive grain. Generally, there is a range distribution of particle sizes. In some embodiments, the abrasive particles can comprise an average particle size of 5 microns or greater, 10 microns or greater, 15 microns or greater, 20 microns or greater, or 25 microns or greater. In some embodiments, the abrasive particles may comprise an average particle size of 1500 microns or less, 1000 microns or less, 750 microns or less, 500 microns or less, 250 microns or less, 100 microns or less, or 50 microns or less. have. It will also be appreciated that the abrasive particles may comprise an average particle size between any of these minimum and maximum values, such as from 5 microns to 1500 microns or even from 10 microns to 50 microns or less.

The amount of abrasive particles in the polishing composition can also vary. In some embodiments, the abrasive composition comprises at least 10 wt.% abrasive particles, at least 15 wt.%, at least 20 wt.%, at least 25 wt.%, at least 30 wt.%, at least 35 wt.%, at least 40 wt.% or more, 45 wt.% or more, 50 wt.% or more, 55 wt.% or more, or 60 wt.% or more of abrasive particles. In some embodiments, the abrasive composition may comprise no more than 75 wt.% abrasive particles, no more than 70 wt.%, no more than 65 wt.%, no more than 60 wt.%, no more than 55 wt.%, or no more than 50 wt.% abrasive particles. can The abrasive grain may fall within any of the minimum or maximum ranges noted above. It will also be appreciated that the amount of abrasive particles in the abrasive composition can be between any of these minimum and maximum values, such as greater than 10 wt.% and less than or equal to 75 wt.% abrasive particles.

Example

Sample fixation polishing buffs were prepared according to the methods disclosed herein. Two different polishing compositions were used. A first uncured polishing composition is shown in Table 1 below. Although ranges are provided for some components, the components of the composition total 100%.

Table 1. First polishing composition ingredient Component weight % polishing powder SiC ANSI 320, 29.2 µm 34.00-38.00 thickener xanthan gum 0.10-1.00 Liquid water 25.00-29.00 Rovene 5550, 50% solids 36.33 humectant 0.17 antifoam 0.17 sum 100.00

A second uncured abrasive composition is shown in Table 2 below. It will be noted that the second abrasive composition contains about 50% less abrasive particles. Although ranges are provided for some components, the components of the composition total 100%.

Table 2. Second polishing composition ingredient Component weight % polishing powder SiC ANSI 320, 29.2 µm 16.00-19.00 thickener xanthan gum 0.25 Liquid water 60.00-65.00 Rovene 5550, 50% solids 18.08 humectant 0.17 antifoam 0.17 sum 100.00

A sample fixed abrasive buff S1 is prepared according to the method disclosed herein comprising applying pressure to a plurality of fabric layers to spread the plurality of fabric layers apart, and coating the buff with a first abrasive composition by rotating the buff in the abrasive composition. was manufactured Control sample C1 was prepared according to the conventional method without applying pressure to the plurality of fabric layers. The resulting weight of the sample is shown in Table 3 below.

Table 3. Sample weight Sample polishing composition gross weight
(gram) uncoated
buff weight
(gram) added weight
(gram) C1 Part 1 - Table 1 60.24 49.41 10.83 S1 Part 1 - Table 1 88.89 49.41 39.48

Sample S1 had a higher weight abrasive composition than control sample C1. This may be due, at least in part, to the application of pressure to the plurality of fabric layers causing the plurality of fabric layers to spread apart.

Additional sample buffs were created. All samples started with the same cotton fabric buff. The control sample (“C1”) remained uncoated with the polishing composition and instead used an abrasive buffing compound externally applied to the buff at 6000-7000 SFPM during buffing. The control sample C1 used is shown in Figure 5A after buffing. Sample S1 was prepared using the same cotton buff and coated according to the methods disclosed herein with the first abrasive composition of Table 1. Sample S1 used is shown in Figure 5B after buffing.

Samples (C1, S1) were tested on brass panels that were 6 inches wide, 24 inches long and 0.125 inches thick. The resulting brass panel buffed by C1 is shown in FIG. 6A. The resulting brass panel buffed by S1 is shown in Figure 6B. Notably, the surface finish buffed by S1 appears to have a better surface finish.

7 shows a chart providing comparative data of surface finish (Ra) of C1 and S1. Most notably, S1 achieved a much better surface finish (Ra). 8 shows a chart providing comparative data of surface finish (Rz) of C1 and S1. Most notably, S1 achieved a much better surface finish (Rz). 9 shows a chart providing comparative data of C1 and S1 cumulative material removal (measured in grams). Most notably, S1 had a much higher cumulative material removal. Surprisingly and beneficially, S1 outperformed C1 in both surface finish (both Ra and Rz) and cumulative material removal.

Eight additional sample fixed abrasive surface buffs were produced and coated with the abrasive composition according to the methods disclosed herein. Sample fixed abrasive buffs were analyzed without testing for abrasive composition and weight of abrasive grains or particles. The results are shown in Table 4 below.

Table 4. Abrasive composition sample weight Sample gross weight
(gram) gross weight
(lb./ream) added weight
(gram) Abrasive content
(gram) outer edge 1.901 39.802 1.295 0.639 medial edge 1.229 25.728 0.623 0.307 base cloth 0.606 12.686 NA NA

Testing was conducted on additional fixed abrasive buffs. Control sample C2 used a cotton cloth buff and remained uncoated with the polishing composition. Control sample C3 was prepared according to a conventional method using a woven cotton buff and applying an abrasive composition to the layer prior to formation of the buff. Sample Fixed Abrasive Buff S2 used a non-woven buff and was left uncoated with the abrasive compound. The sample fixed polishing buff S3 used a non-woven buff, including applying pressure to a plurality of fabric layers to spread the plurality of fabric layers apart, and coating the buff with a first polishing composition by rotating the buff in the polishing composition. was prepared according to the method disclosed herein.

Samples C2, C3, S2 and S3 were tested on substantially similar brass workpieces. C2 and S2 were tested using a bar compound applied to the buff during buffing. C3 and S3 were tested as manufactured.

10 shows a chart providing comparative data of surface finish (Ra) of C2, C3, S2 and S3. Most notably, S3 achieved significantly better surface finish (Ra) compared to C2, C3 and S2. Additionally, S3 also achieved a better surface finish in a much shorter time compared to C2, C3 and S2.

11 shows a chart providing comparative data of surface finish (Rz) of C2, C3, S2 and S3. Most notably, S3 achieved a significantly better surface finish (Rz) compared to C2, C3 and S2. Additionally, S3 also achieved a better surface finish in a much shorter time compared to C2, C3 and S2.

12 shows a chart providing comparative data of cumulative material removal (measured in grams) of C2, C3, S2 and S3. Most notably, S3 had a much higher cumulative material removal compared to C2, C3 and S2.

13 shows a chart providing comparative data on the power requirements (measured in horsepower (Hp)) of C2, C3, S2 and S3. Most notably, S3 required significantly less power to achieve the desired surface finish (both Ra and Rz) while achieving higher cumulative material removal compared to C2, C3 and S2. Thus, S3 outperformed C2, C3 and S2 in both surface finish (both Ra and Rz) and cumulative material removal rate while requiring significantly less power to achieve these results.

Sample S3 was submitted for comparison of the amount of coating and abrasive grains or particles in the samples. A sample strip 0.5 inch wide (measured circumferentially) and 1.25 inch long (measured radially) was cut from disassembled sample S3 as shown in FIG. 14 . The sample weight average of the sample strip was obtained and recorded. These sample strips were analyzed by subjecting the sample strips to a so-called "burning" process at 450 degrees Celsius for 10 hours.

Weight loss was recorded. The sample strip appeared to have some inorganic residue (K-Cl phase) after the burning process. To find the exact amount of abrasive grains (SiC grains), the ash remaining from the combustion process was treated with 10% by volume hydrochloric acid (HCl). The amount of remaining abrasive grain was recorded. The results are shown in Table 5 below.

Table 5. Abrasive composition sample weight Sample sample weight
(g) Coating (Resin & Grain)
(g) Inorganic residues after burning
(g) Inorganic coating Wt.%
(g) Grain after HCl
(g) Grain Wt.% in coating after HCl
(g) outer edge 1.9190 1.313 0.9083 69.2 0.8972 68.3 medial edge 1.2442 0.6382 0.4409 69.1 0.4289 67.2

As shown in Table 5, the outer edge had a higher overall weight and higher overall abrasive composition coating. As a result, the outer edge had a higher grain concentration at the outer edge (0.8972 g) compared to the concentration of abrasive grain at the inner edge (0.4289 g). Most notably, the outer edge contained approximately 52.19% higher concentration at the outer edge for the tested sample S3.

It will be appreciated that embodiments of abrasive articles are disclosed herein that may include one or more of the following embodiments:

Embodiment 1. A fixed abrasive buff comprising: a central hub; a plurality of fabric layers attached to the central hub; and an abrasive composition comprising a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder, wherein the content of abrasive particles at the outer edge of the plurality of fabric layers is higher than the content of abrasive particles at the inner edge of the plurality of fabric layers. .

Embodiment 2. The method of Embodiment 1, wherein the abrasive particle content at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more, Fixed abrasive buffs higher than 25%, 30%, 35%, 40%, 45%, or 50% higher.

Embodiment 3. The fixed abrasive buff of Embodiment 1, wherein the added weight of the abrasive composition at the outer edges of the plurality of fabric layers is higher than the added weight of the abrasive composition at the inner edges of the plurality of fabric layers.

Embodiment 4 The method of Embodiment 3, wherein the added weight of the abrasive composition at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more than the added weight of the abrasive composition at the inner edge of the plurality of fabric layers. Fixed abrasive buffs higher than 25%, 30%, 35%, 40%, 45%, or 50%.

Embodiment 5 The fixed abrasive buff of Embodiment 1, wherein a total weight of the fixed abrasive buff at the outer edges of the plurality of fabric layers is higher than a total weight at the inner edges of the plurality of fabric layers.

Embodiment 6 The method of Embodiment 5, wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more than the total weight at the inner edge of the plurality of fabric layers, Fixed abrasive buffs higher than 25%, 30%, 35%, 40%, 45%, or 50% higher.

Embodiment 7. The fixed abrasive buff of any one of embodiments 1 to 6, wherein the inner edge is adjacent to the center hub and the outer edge is radially farthest from the center hub.

Embodiment 8. The fixed abrasive buff of embodiment 1, wherein the plurality of fabric layers comprises a woven fabric, a non-woven fabric, or a combination thereof.

Embodiment 9 The method of embodiment 8, wherein the plurality of fabric layers is at least 2 layers, at least 4 layers, at least 6 layers, at least 8 layers, at least 10 layers, at least 12 layers, at least 15 layers, Fixed polishing comprising 20 or more layers or 25 or more layers to 100 or less layers, 50 or less layers, 25 or less layers, 20 or less layers, 15 or less layers, or 12 or less layers buff.

Embodiment 10. The set abrasive buff of Embodiment 1, wherein the abrasive composition is dispersed on or within each of the plurality of fabric layers.

Embodiment 11. The polishing composition of Embodiment 1 comprising a fixed abrasive buff comprising: 10 wt.% to 80 wt.% of a polymeric binder; and 20 wt.% to 90 wt.% of abrasive particles.

Embodiment 12. The set abrasive buff of embodiment 11, wherein the polymeric binder comprises a self-crosslinking carboxylated styrene-butadiene composition.

Embodiment 13. The fixed abrasive buff of Embodiment 11, wherein the abrasive particles include silicon carbide.

Embodiment 14. The fixed abrasive buff of Embodiment 13, wherein the abrasive particles comprise an average particle size of 5 micrometers or greater, 10 micrometers or greater, 15 micrometers or greater, 20 micrometers or greater, or 25 micrometers or greater.

Embodiment 15. The fixed abrasive buff of embodiment 14, wherein the abrasive particles comprise an average particle size of 500 microns or less, 250 microns or less, 100 microns or less, or 50 microns or less.

Embodiment 16. A method of forming a fixed abrasive buff comprising: providing an uncoated buff comprising a central hub and a plurality of fabric layers attached to the central hub; applying pressure to the plurality of fabric layers to spread the plurality of fabric layers apart; and coating the buff with the polishing composition by rotating the buff in the polishing composition.

Embodiment 17 The method of Embodiment 16, wherein the content of abrasive particles at the outer edge of the plurality of fabric layers is higher than the content of abrasive particles at the inner edge of the plurality of fabric layers.

Embodiment 18. The method of Embodiment 17, wherein the abrasive particle content at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more than the abrasive particle content at the inner edge of the plurality of fabric layers, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, or 50% or more higher.

Embodiment 19 The method of any one of embodiments 16-18, wherein the added weight of the polishing composition at the outer edge of the plurality of fabric layers is higher than the added weight of the polishing composition at the inner edge of the plurality of fabric layers.

Embodiment 20 The method of Embodiment 19, wherein the added weight of the polishing composition at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% greater than the added weight of the polishing composition at the inner edge of the plurality of fabric layers. Higher than, 25% or higher, 30% or higher, 35% or higher, 40% or higher, 45% or higher, or 50% or higher.

Embodiment 21 The method of any of embodiments 16-20, wherein a total weight of the set abrasive buff at the outer edges of the plurality of fabric layers is greater than a total weight at the inner edges of the plurality of fabric layers.

Embodiment 22 The method of Embodiment 21, wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more than the total weight at the inner edge of the plurality of fabric layers, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, or 50% or more, or combinations thereof.

Embodiment 23. The method of any one of embodiments 16-22, wherein applying pressure to the plurality of fabric layers comprises applying pressurized air toward the plurality of fabric layers, thereby injecting the plurality of fabric layers onto a sidewall of a container containing the polishing composition. or by a combination thereof.

Embodiment 24 The method of any one of Embodiments 16 to 23, comprising: removing the fixed abrasive buff from the polishing composition; spinning off the excess abrasive composition by rotating the fixed abrasive buff; and curing the polishing composition on the fixed abrasive buff.

Embodiment 25. The fixed abrasive buff of any one of embodiments 1 to 15 or the method of any one of embodiments 16 to 24, wherein the added weight of the polishing composition is at least 15 grams, at least 16 grams, at least 17 grams, at least 18 grams , 19 grams or more, 20 grams or more, 21 grams or more, 22 grams or more, 23 grams or more, 24 grams or more, or 25 grams or more.

This written description discloses embodiments, including the best mode, and also uses examples that will enable those skilled in the art to make and use the present invention. The patentable scope is defined by the claims and may include other examples that occur to one skilled in the art. Such other examples are within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. it is intended

Note that not all of the activities described above are required in the general description or example, some of the specific activities may not be required, and one or more additional activities may be performed in addition to those described. Also, the order in which activities are listed is not necessarily the order in which they are performed.

In the foregoing specification, concepts have been described with reference to specific embodiments. However, one skilled in the art recognizes that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and drawings are to be regarded in an illustrative rather than restrictive sense, and all such modifications are intended to be included within the scope of the invention.

As used herein, the terms "comprises", "comprising", "includes", "including", "has", "having" or other variations thereof are intended to include a non-exclusive inclusion. For example, a process, method, article, or device that includes a list of features is not necessarily limited to only those features, but may include other features not explicitly listed or unique to such process, method, article, or device. can include Also, unless expressly stated otherwise, “or” refers to an inclusive-or and not an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

Also, the use of “a” or “an” is used to describe elements and components described herein. This is done for convenience only and to give a general sense of the scope of the present invention. This description should be read to include one or at least one, and the singular also includes the plural unless it is clear to the contrary.

Advantages, other advantages, and solutions to problems have been described above with respect to specific embodiments. However, an advantage, advantage, solution to a problem, and any feature(s) that can give rise to or make any advantage, advantage, or solution significant, necessary, or essential to any or all claims. It should not be interpreted as a characteristic.

After reading the specification, skilled artisans will understand that, for clarity, certain features that are described herein in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, for brevity, various features that are described in the context of a single embodiment can also be provided separately or in any subcombination. Further, references to values stated in ranges include each and every value within that range.

Claims (15)

Fixed abrasive buffs that include:
central hub;
a plurality of fabric layers attached to the central hub; and
An abrasive composition comprising a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder, wherein the abrasive content of the abrasive particles at the outer edge of the plurality of fabric layers is higher than the content of abrasive particles at the inner edge of the plurality of fabric layers. composition. The method of claim 1, wherein the content of abrasive particles at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more, 25% or more than the content of abrasive particles at the inner edge of the plurality of fabric layers, Fixed abrasive buffs higher than 30%, 35%, 40%, 45%, or 50% higher. The fixed abrasive buff of claim 1 , wherein the added weight of the abrasive composition at the outer edges of the plurality of fabric layers is higher than the added weight of the abrasive composition at the inner edges of the plurality of fabric layers. 4. The method of claim 3, wherein the added weight of the polishing composition at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more, 25% or more than the added weight of the polishing composition at the inner edge of the plurality of fabric layers. Fixed abrasive buffs higher than 30% or higher, 35% or higher, 40% or higher, 45% or higher, or 50% or higher. The fixed abrasive buff according to claim 1, wherein the total weight of the fixed abrasive buff at the outer edges of the plurality of fabric layers is higher than the total weight at the inner edges of the plurality of fabric layers. 6. The method of claim 5, wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is 10% or more, 15% or more, 20% or more, 25% or more than the total weight at the inner edge of the plurality of fabric layers, Fixed abrasive buffs higher than 30%, 35%, 40%, 45%, or 50% higher. 2. The fixed abrasive buff of claim 1, wherein the inner edge is adjacent to the center hub and the outer edge is radially farthest from the center hub. 2. The fixed abrasive buff of claim 1, wherein the plurality of fabric layers comprises a woven fabric, a non-woven fabric, or a combination thereof. 9. The method of claim 8 wherein the plurality of fabric layers is at least 2 layers, at least 4 layers, at least 6 layers, at least 8 layers, at least 10 layers, at least 12 layers, at least 15 layers, at least 20 layers or a fixed abrasive buff comprising at least 25 layers and at most 100 layers, at most 50 layers, at most 25 layers, at most 20 layers, at most 15 layers, or at most 12 layers. 10. The fixed abrasive buff of claim 9, wherein the abrasive composition is dispersed on or within each of the plurality of fabric layers. The fixed abrasive buff of claim 1, wherein the abrasive composition comprises:
10 wt.% to 80 wt.% of a polymeric binder; and
20 wt.% to 90 wt.% of abrasive particles. 12. The set abrasive buff of claim 11, wherein the polymeric binder comprises a self-crosslinking carboxylated styrene-butadiene composition. 12. The method of claim 11, wherein the abrasive particles are silica, alumina (fused or sintered), zirconia, rconia/alumina oxide, zirconium silicate, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, A fixed abrasive buff comprising titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery or combinations thereof. 14. The fixed abrasive buff of claim 13, wherein the abrasive particles comprise an average particle size of 5 micrometers or greater, 10 micrometers or greater, 15 micrometers or greater, 20 micrometers or greater, or 25 micrometers or greater. 15. The fixed abrasive buff of claim 14, wherein the abrasive particles comprise an average particle size of 500 microns or less, 250 microns or less, 100 microns or less, or 50 microns or less.

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