RU2452613C2 - Abrasive article and method of its production and application - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to machining and may be used for surface cleaning, grinding and finishing. Abrasive article comprises porous abrasive material, nonwoven filtration material, second nonwoven filtration material, and, if required, porous jointing layer. Multiple holes in porous abrasive elements are communicated with first nonwoven filtration material to allow particles to flow from outer abrasive surface of porous abrasive element to second filtration material. Invention covers also methods of production and application of said abrasive articles.

EFFECT: perfected working performances, simplified dust collection.

18 cl, 6 dwg, 4 tbl, 7 ex

Description

BACKGROUND OF THE INVENTION

Abrasive products are used in industry for cleaning, lapping, grinding and polishing. They can be made in a mass of modified forms, such as tapes, disks, panels, and have various sizes.

Typically, when using abrasive articles having a “sheet shape” (ie, disks and panels), a support substrate is used to fix or fasten the abrasive article to the lapping tool. Some types of support substrates have dust extraction holes connected by a series of grooves. In order to combat the accumulation of sawdust on the abrasive surface of said abrasive product (here, the term “sawdust” refers to loose material, for example dust and shavings generated during abrasive processing), these dust collection openings are usually connected to a vacuum source. It is known that removing sawdust from an abrasive surface improves the performance of an abrasive article.

Some abrasive tools are equipped with integral vacuum systems with dust collectors. The extraction and retention capabilities of these abrasive tools are limited, in particular, by the requirements for suction of existing abrasive discs, imposed by the respective supporting substrates.

In some abrasive product designs, dust is collected in a complex dust collector system through a hose connected to the abrasive product. However, the operator of an abrasive tool does not always have dust collection systems. Moreover, the use of dust collection systems that require the use of hoses can be inconvenient and may interfere with the handling of the operator of such an abrasive tool.

SUMMARY OF THE INVENTION

One of the objects of the present invention is an abrasive article, consisting of: a porous abrasive material having: an abrasive layer adjacent to and attached to a first surface of a substrate, said abrasive layer consists of a plurality of abrasive particles attached to said first surface of said substrate with at least one binder moreover, the specified abrasive layer has an external abrasive surface, and the specified substrate has a second surface opposite the specified first surface at azannoy substrate, and with said outer abrasive surface to said second surface of said substrate passes a plurality of apertures;

a first non-woven filter material having a first surface and a second surface opposite said first surface, said first surface of said first non-woven filter material adhering to and attached to said second surface of said substrate, wherein said first non-woven filter material consists of a plurality of fibers; and

a second non-woven filter material having a first surface and a second surface opposite said first surface, wherein said first surface of said second non-woven filter material adheres to and is attached to said second surface of said first non-woven filter material, and wherein said second non-woven filter material consists of a plurality of fibers ;

where multiple openings are combined with said first nonwoven filter material, allowing particles from said external abrasive surface to pass onto said second filter material, and where, in an unused condition, at least a portion of said abrasive article exhibits a pressure drop in the range of 0.2 to 20 mm water column according to the Differential Pressure Test.

Another object of the present invention is a method of manufacturing an abrasive product, including:

the preparation of a porous abrasive material having: an abrasive layer adjacent and attached to the first surface of the substrate, the specified abrasive layer consists of many abrasive particles attached to the specified first surface of the specified substrate with at least one binder, and the specified abrasive layer has an external abrasive surface, and the specified substrate has a second surface opposite the specified first surface of the specified substrate, and with the specified external abrasive surface on said second surface of said substrate passes through a plurality of holes;

preparing a first non-woven filter material, said first non-woven filter material having a first surface and a second surface opposite said first surface, where said first non-woven filter material contains a plurality of fibers and where said first surface of said first non-woven filter material is adjacent to said second surface of said substrate ;

preparing a second non-woven filter material, said second non-woven filter material having a first surface and a second surface opposite said first surface, where said second non-woven filter material contains a plurality of fibers and where said first surface of said second non-woven filter material is adjacent to said second surface of said first filter material;

attaching said first non-woven filter material to said second surface of said substrate; and

attaching said second non-woven filter material to said first non-woven filter material;

where multiple openings are combined with said first nonwoven filter material, allowing particles from said external abrasive surface to pass onto said second filter material, and where, in an unused condition, at least a portion of said abrasive article exhibits a pressure drop in the range of 0.2 to 20 mm water column according to the Differential Pressure Test.

Another subject of the present invention is an abrasive article consisting of:

a porous abrasive material having: an abrasive layer adjacent to and attached to a first surface of a substrate, said abrasive layer consists of a plurality of abrasive particles attached to said first surface of said substrate with at least one binder, said abrasive layer having an external abrasive surface, said the substrate has a second surface opposite the specified first surface of the specified substrate, and from the specified external abrasive surface to the specified second the surface of said substrate passes through many holes;

a first non-woven filter material having a first surface and a second surface opposite the first surface, said first surface of said first non-woven filter material adhering to and attached to said second surface of said substrate, where said first non-woven filter material consists of a plurality of fibers and where said first non-woven filter material has a thickness of 1 to 25 mm and a bulk density of 0.04 to 0.5 grams per cubic centimeter; and

a second non-woven filter material having a first surface and a second surface opposite said first surface, said first surface of said second non-woven filter material adhering to and attached to said second surface of said first filter material, wherein said second non-woven filter material consists of a plurality of fibers, and where the specified second non-woven filter material has a thickness of from 0.5 to 15 mm and bulk density from 0.04 to 0.5 grams per cubic centimeter; and

where these numerous holes are combined with the specified first non-woven filter material, allowing particles from the specified external abrasive surface to pass on the specified second filter material.

Another object of the present invention is a method of manufacturing an abrasive product, including:

the preparation of a porous abrasive material having: an abrasive layer adjacent and attached to the first surface of the substrate, the specified abrasive layer consists of many abrasive particles attached to the specified first surface of the specified substrate with at least one binder, and the specified abrasive layer has an external abrasive surface, and the specified substrate has a second surface opposite the specified first surface of the specified substrate, and with the specified external abrasive surface on said second surface of said substrate passes through a plurality of holes;

the preparation of the first non-woven filter material having a first surface and a second surface opposite the specified first surface, where the specified first surface of the specified first non-woven filter material is adjacent to the specified second surface of the specified substrate, where the specified first non-woven filter material consists of many fibers, and where the specified second non-woven filter material has a thickness of 0.5 to 15 mm and a bulk density of 0.04 to 0.5 grams per cubic centimeter;

the preparation of a second non-woven filter material having a first surface and a second surface opposite the specified first surface, where the specified first surface of the specified second non-woven filter material is adjacent to the specified second surface of the specified second non-woven filter material, where the specified second non-woven filter material has a thickness of from 0.5 to 15 mm and bulk density from 0.04 to 0.5 grams per cubic centimeter;

attaching said first non-woven filter material to said second surface of said substrate; and

attaching said second non-woven filter material to said first filter material, wherein said multiple holes are combined with said first non-woven filter material, allowing particles from said external abrasive surface to pass onto said second filter material.

In some embodiments of the present invention, said porous abrasive material comprises coated abrasive material having openings. In some embodiments, the porous abrasive material comprises a mesh abrasive material. In some embodiments of the present invention, said first non-woven filter material and said second non-woven filter material are attached to each other by needle punching or stitch binding. In some embodiments of the present invention, said porous abrasive is adhered to said first non-woven filter medium with glue. In some embodiments of the present invention, said first non-woven filter material is adhered to said second non-woven filter material with glue. In some embodiments of the present invention, at least one of said first non-woven filter material or a second non-woven filter material comprises synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof. In some embodiments, implementation of the present invention, the specified substrate is selected from the group consisting of metal foil, paper, fabric and polymer film. In some embodiments of the present invention, at least one of said first non-woven filter material or a second non-woven filter material comprises an aerofoil microfiber cloth. In some embodiments of the present invention, at least one of said first non-woven filter material or a second non-woven filter material has an electret charge. In some embodiments of the present invention, said second surface of said substrate and said first surface of said first non-woven filter material have the same extent, and said second surface of said first non-woven filter material and said first surface of said second non-woven filter material have the same extent. In some embodiments of the present invention, at least one of said first or second nonwoven filter material has an outer edge, most of which is sealed. In some embodiments of the present invention, said abrasive article is an abrasive wheel.

In some embodiments, implementation of the present invention, the porous mounting fabric is attached to the specified second surface of the specified second non-woven filter material. In some embodiments of the present invention, said porous attachment layer has a hinge (loop) and a hook (hook) of a two-element mechanical engagement system. In some embodiments of the present invention, said first non-woven filter material, said second non-woven filter material, and said porous abrasive layer are attached to each other by needle-piercing or stitch bonding.

The abrasive articles according to the subject matter of the present invention are useful, for example, for abrasive treatment of a part surface in a manner comprising bringing said surface into contact with said abrasive article and relative movement of said abrasive article and said surface to mechanically change said surface.

The abrasive articles according to the subject matter of the present invention are advantageously particularly useful for such abrasive machining operations that produce a significant amount of particles (eg, sawdust), and in at least some embodiments of the present invention can effectively capture at least 40, 50 (i.e. most), 60, 70, 80, or even more than 90 percent of the particles formed during such an abrasive treatment, for example, if used in combination with a tool equipped with a source m vacuum.

In the context of the present invention

the term "air resistance" means the resistance to the passage of air through the thickness of the nonwoven fabric of the abrasive product, and when used for comparison purposes, all values of air resistance should be measured under the same conditions;

the term "nonwoven filter material" means a material having an internal pore space and consisting essentially of a plurality of interwoven and / or bonded fibers obtained by a method other than textile or knitting; and

the term “thickness” as applied to non-woven filter media refers to the thickness of the non-woven fabric measured in accordance with ASTM D5736-95 (reapproved in 2001) “Standard Test Method for Thickness of Highloft Nonwoven Fabrics” highloft (nonwovens) using a pressure plate force of 0.002 psi (13.8 Pa).

BRIEF DESCRIPTION OF THE DRAWINGS

On figa presents partially cut away to demonstrate the layers forming this product, a perspective view of an illustrative abrasive product according to one of the embodiments of the present invention.

On figv presents a schematic cross section of the abrasive product shown in figa.

On figa presents a top view of an illustrative porous abrasive material used in abrasive products according to the subject of the present invention.

On figv presents a cross section of the porous abrasive material shown in figa.

Figure 3 presents a top view of an illustrative porous abrasive material used in abrasive products according to the subject of the present invention, partially cut away to demonstrate the components forming the specified abrasive layer; and

4 is a scaled top view showing an illustrative example of a perforation 400 for a 5-inch (127 mm) coated abrasive wheel.

These drawings, which are theoretical, are intended solely to illustrate the abrasive product that is the subject of the present invention, and are not limiting.

DETAILED DESCRIPTION

1A is a partially cut away perspective view of an illustrative abrasive article 102 (shown as an abrasive wheel). As shown in FIG. 1A, said abrasive article 102 has a porous abrasive element 104, a first non-woven filter material 120, a second non-woven filter material 140, and an optional porous attachment layer 146. Said porous abrasive element 104 has a plurality of holes allowing particles (e.g., sawdust formed during abrasive processing) pass through the specified porous abrasive element 104. Then the particles are captured by the specified filter material of the specified abrasive product. The optional seal 105 seals the outer edge 106 (shown in FIG. 1B) of the first and second non-woven filter media 120, 140, respectively, thereby preventing lateral ejection of particles not retained by said abrasive article 102.

FIG. 1B is a schematic cross-sectional view of the abrasive article 102 shown in FIG. 1A. As shown in FIG. 1B, said abrasive article 102 has several layers. Said first non-woven filter material 120 has a first surface 122 and a second surface 124 opposite to said first surface 122. Said second non-woven filter material 140 has a first surface 142 and a second surface 144 opposite to said first surface 142. Said first surface 122 of said first non-woven filter material 120 is adjacent to the specified porous abrasive element 104. The specified second surface 124 of the specified first non-woven filter material 120 of the abutment t to said second surface 142 of said second non-woven filter material 140. A porous mounting layer 146 abuts against said second surface 144 of said second non-woven filter material 140. Said porous abrasive element and various layers of filter material of said abrasive product are bonded to each other in a manner that does not prevents the passage of particles from one layer to the next, although there may be some partial or minor interference with the passage of particles. In some embodiments of the present invention, said porous abrasive element and various layers of filter material of said abrasive article are bonded to each other in a manner that does not substantially prevent particles from passing from one layer to the next. In some embodiments of the present invention, the degree to which particles can pass through said abrasive article can be limited, at least in part, by introducing adhesive between said porous abrasive member and said first nonwoven filter material or between said first nonwoven filter material and said second nonwoven filter material. The degree of restriction can be minimized by intermittent application of the adhesive between the layers, for example, as separate sections of the adhesive (for example, droplet spraying or extrusion with insufficient supply) or separate lines of adhesive (for example, by vortex spraying of hot melt or using a coating unit with a figure roller )

On figa presents a top view of an illustrative abrasive material with a coating used to form the specified porous abrasive element. On figv presents a cross section of the specified porous abrasive element shown in figa. As shown in FIG. 2B, said porous abrasive element 204 includes a substrate 206 having a first surface 208 and a second surface 210, a fixing coating 214, a plurality of abrasive particles 212 and an adhesive coating 215. As shown in FIG. 2A, said porous abrasive element 204 has many holes (not shown in FIG. 2B).

Figure 3 presents a top view of an illustrative mesh abrasive material used to form the specified porous abrasive element. Figure 3 includes a partial section to demonstrate the components forming the specified abrasive layer. As shown in FIG. 3, said porous abrasive element 304 includes an open cell mesh substrate 306, a coating 314, a plurality of abrasive particles 312, and an adhesive coating 315. Said porous abrasive element 304 has a plurality of openings passing through said porous abrasive element. Holes 316 are formed by holes 318 in said mesh substrate 306.

The specified mesh substrate can be made of any porous material, including, for example, perforated films, non-woven materials or woven or knitted fabrics. In the embodiment of the present invention shown in FIG. 3, said mesh substrate 306 is a perforated film. The specified film for the specified substrate can be made of metal, paper or polymeric materials, including molded thermoplastics and molded thermosets. In some embodiments of the present invention, said mesh substrate is perforated or cut and stretched sheet material. In some embodiments of the present invention, said mesh substrate is made of fiberglass, nylon, polyester, polypropylene or aluminum.

Said holes 318 in said mesh substrate 306 can generally have a square shape, as shown in FIG. 3. In other embodiments of the present invention, said openings may have a different geometric shape, including, for example, a rectangle, circle, oval, triangle, parallelogram, polygon, or a combination of these shapes. Said holes 318 in said mesh substrate 306 may be uniform in size and evenly distributed, as shown in FIG. In other embodiments of the present invention, said openings may be unevenly distributed, which is achieved, for example, by using an arbitrary pattern of hole patterns, alternating sizes and shapes of holes, or any combination of a random arrangement, arbitrary shapes, and arbitrary sizes.

Alternatively, a mesh abrasive with a woven or knitted backing can be used to form said porous abrasive element. A woven substrate is usually formed by a plurality of generally parallel warp elements extending in the first direction, and a plurality of generally parallel weft elements extending in the second direction. The weft elements and the warp elements of said mesh substrate intersect, forming a plurality of holes. The specified second direction may be perpendicular to the specified first direction in order to form square holes in said woven mesh substrate. In some embodiments of the present invention, said first and second directions intersect to form a diamond pattern. These holes may have a different geometric shape, including, for example, a rectangle, circle, oval, triangle, parallelogram, polygon, or a combination of these shapes. In some embodiments of the present invention, warp and weft elements are yarns woven “one on top of the other”.

These warp and weft elements can be combined in any manner known to those skilled in the art, for example, weaving, stitch bonding or gluing. These warp and weft elements may be fibers or threads of various nature or combinations of the above. These warp and weft elements can be made from any materials known to those skilled in the art, including, for example, artificial fibers, natural fibers, fiberglass and metal. In some embodiments of the present invention, the warp and weft elements are monofilament of a thermoplastic material or metal wire. In some embodiments of the present invention, said woven mesh substrate is made of nylon, polyester or polypropylene.

The specified porous abrasive element, as a mesh abrasive, a perforated coated abrasive, and another abrasive, may have holes characterized by different throughput areas. The "cross-sectional area" of the hole in the specified porous abrasive element refers to the area of the specified hole, measured by the thickness of the specified porous abrasive element (i.e., the area bounded by the perimeter of the material forming the specified hole through which a three-dimensional object can pass). Suitable porous abrasive elements typically have an average flow area of at least about 0.5 mm ² per hole. In some embodiments of the present invention, said porous abrasive element has an average flow area of at least about 1 mm ² per hole. In other embodiments of the present invention, said porous abrasive element has an average flow area of at least about 1.5 mm ² per hole.

The specified porous abrasive element, like woven, perforated or otherwise, is characterized by the total area of the cross-section, which determines the amount of air that can pass through the specified porous abrasive element, as well as the surface area and characteristics of the specified porous abrasive layer. "Total flow area" of the specified porous abrasive element refers to the total area of the flow section of these holes, measured by the area enclosed within the perimeter of the specified porous abrasive element. Porous abrasive elements have a total flow area equal to at least about 0.01 cm ² per 1 cm ^{2 of the} specified abrasive layer (i.e., the flow area is 1 percent). In some embodiments of the present invention, said porous abrasive member has a total throughput area of at least about 0.03 cm ² per 1 cm ^{2 of} said abrasive layer (i.e., the throughput area is 3 percent). In other embodiments of the present invention, said porous abrasive element has a total flow area equal to at least about 0.05 cm ² per 1 cm ^{2 of} said abrasive layer (i.e., the flow area is 5 percent).

Typically, said porous abrasive element has a total flow area of less than at least about 0.95 cm ² per cm ^{2 of} said abrasive layer (i.e., the flow area is 95 percent). In some embodiments of the present invention, said porous abrasive element has a total flow area of less than at least about 0.9 cm ² per 1 cm ^{2 of} said abrasive layer (i.e., the flow area is 90 percent). In other embodiments of the present invention, said porous abrasive element has a total throughput area of less than at least about 0.80 cm ² per 1 cm ^{2 of} said abrasive layer (i.e., 80 percent throughput area).

As discussed above, said porous abrasive element, like coated perforated abrasive, coated mesh abrasive, non-woven abrasive, and other abrasive, contains many abrasive particles and at least one bond (binder). In some embodiments of the present invention, said abrasive layer has a fixing coating, a sizing coating, an upper sizing coating, or a combination of the above. In some embodiments of the present invention, said abrasive layer is obtained, at least in part, by curing a suspension of abrasive particles in a binder precursor. Typically, a coated abrasive fixing layer is obtained by coating at least a portion of a substrate (e.g., a treated or untreated backing, mesh or nonwoven fiber web) with a fixing layer precursor comprising a first binder precursor.

These substrates can be subjected to one or more types of processing (for example, applying to the back side of the release (backsize), separation (presize), intermediate (subsize) coatings or proptics). Suitable substrates are well known in the field of abrasive products and may include, for example, metal foil, paper, fabrics (e.g., knitted, non-woven or woven (including mesh and dense fabrics)), woven networks, polymer film (e.g., including thermoplastic materials, such as polyester, polyethylene and polypropylene) and combinations of the above. In some embodiments of the present invention, said substrate does not have a layered structure.

Preferably, said substrate is relatively thin and flexible. For example, in some embodiments of the present invention, said substrate may have a thickness of less than 1 millimeter, less than 0.5 mm, or even less than 0.1 mm. In some embodiments of the present invention, holes, slots, or other pores extending through the thickness of said substrate are characterized by a substantially uniform cross section along their entire length.

Then, the abrasive particles are at least partially embedded (for example, electrostatically or by spraying) into the precursor of the fixing layer containing the precursor of the first binder, and said predecessor of the fixing layer is at least partially cured. Electrostatic application of abrasive particles usually allows you to get vertically oriented abrasive particles. In the context of abrasive products, the term “vertical orientation” refers to a situation in which the largest dimensions of most abrasive particles are mostly oriented perpendicular (i.e., at angles of 60 to 120 degrees) to the substrate. Other methods can also be used to achieve the vertical orientation of the abrasive particles.

Further, by coating at least a portion of said fixing layer and abrasive particles with a sizing precursor comprising a second binder precursor (which may be the same or different from said first binder precursor) and at least partially curing said sizing precursor, a sizing layer is prepared. In some coated abrasive products, at least a portion of said sizing layer is coated with a topcoat. If used, said topcoat layer typically contains grinding aids and / or antifouling agents.

Typically, a binder is formed by curing (for example, thermal or under the influence of electromagnetic or particle radiation) of the binder precursor. Binder precursors suitable for use in fixing, sizing, topcoats and suspension coatings are well known in the abrasive industry and include, for example, free radical polymerizable monomer and / or oligomer, epoxy resins, acrylic resins, urethane resins, phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, aminos, cyanate resins, or combinations of the above. Suitable binder precursors include thermosetting resins and radiation curable resins, which can be cured, for example, thermally and / or by radiation.

As is well known in the industry, in combination with binder precursors, catalysts, initiators and / or hardeners can be used, usually in effective amounts.

Suitable abrasive products for coated abrasive particles include, for example, any known abrasive particles or materials commonly used in abrasive products. Examples of abrasive particles for coated abrasives include, for example, fused alumina (electrocorundum), heat-treated alumina, white electrocorundum, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride , garnet, fused alumina-zirconia, obtained by the sol-gel method, abrasive particles, silica, iron oxide, chromium oxide, cerium oxide, zirconium oxide, titanium oxide, silicates, metal carbonates (such as calcium carbonate (e.g. chalk, calcite, marl, travertine, marble and limestone), calcium-magnesium carbonate (dolomite), sodium carbonate, magnesium carbonate, silicon dioxide (e.g. quartz, glass beads, glass balls and fiberglass), silicates (e.g. talc, clay, (montmorillonite) feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate), metal sulfates (e.g. calcium sulfate, barium sulfate, sodium sulfate, aluminum-sodium sulfate, aluminum sulfate), gypsum, aluminum trihydrate, graphite, metal oxides (for example p, tin oxide, calcium oxide), alumina, titanium dioxide and metal sulfites (e.g., calcium sulfite), metal particles (e.g., tin, lead, copper particles), polymer abrasive particles (e.g., polycarbonate, polyetherimide, polyester, polyethylene, polysulfone, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, acetal polymers, polyvinyl chloride, polyurethanes, nylon), polymer abrasive particles formed from cross-linked polymers (e.g. phenolic resins, aminos, urethane resins, epoxies, melamine-formaldehyde resins, acrylate resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins) and combinations of the above. Said abrasive particles may also be agglomerates or composites comprising additional components, such as, for example, a binder. The selection criteria for abrasive particles used for a particular application typically include: wear resistance, cutting speed, surface treatment of the substrate, grinding efficiency, and product cost.

In addition, coated abrasive elements may contain optional additives, such as surface modifiers of abrasive particles, binders, plasticizers, fillers, blowing agents, fibers, antistatic agents, initiators, suspending agents, photosensitizers, lubricants, wetting agents, surfactants, pigments, dyes, UV stabilizers and suspending agents. Amounts of these materials are selected so as to provide the desired properties. Additives may also be included in the binder, applied in the form of a separate coating, contained in the pores of the agglomerate, or used in combinations of the foregoing.

If the specified abrasive element is not porous in nature (for example, due to the nature of the substrate), the abrasive element can be perforated, for example, by mechanical perforation (for example, using a die cut), laser perforation, or any other suitable method. Any perforation pattern may be used. The holes can be, for example, round or elongated, straight, arcuate, or have a complex shape. The specified porous abrasive element must have a porosity sufficient for particles (for example, chips) to pass from the outer abrasive surface to the first and second filter material at a speed comparable to the rate of their formation.

Examples of commercially available coated porous abrasive products suitable for use as a porous abrasive element include a material sold under the trade name "NORTON MULTI-AIR" manufactured by Saint-Gobain Abrasives GmbH, Wesseling, Germany (Wesseling, Germany) ), and coated abrasives sold under the trade name "CLEAN SANDING DISC", manufactured by 3M Company, Saint Paul. Minnesota (Saint Paul, Minnesota, USA).

In some embodiments of the present invention, said first and / or second non-woven filter material has an average thickness in the range of at least 0.5, 1, or even at least 5 mm, up to 10 or 15 mm. In other embodiments of the present invention, said first non-woven filter element may have a thickness of up to 20, or even 30 mm, or a greater thickness. In some embodiments of the present invention, said first non-woven filter material has an average thickness of less than about 20 mm.

In some embodiments of the present invention, said first and / or second non-woven filter material has a bulk density of 0.04 to 0.5 g / cm ³ . For example, said first filter material may have a bulk density of from 0.75 to 0.4 g / cm ³ or from 1 to 0.3 g / cm ³ .

In some embodiments of the present invention, said first filter material is thicker and optionally less dense than said second filter material. In other embodiments of the present invention, said second filter material is thicker and optionally less dense than said first filter material.

Said first and / or second filter material of said abrasive article may have an electrostatic charge. The presence of an electrostatic charge increases the ability of these filter materials to remove solid particles from the fluid stream by increasing the attraction between the particles and the surface of the filter material. Unstable particles passing near the fibers of these filter materials are more easily removed from the fluid stream, and the colliding particles adhere more firmly. Passive electrification is created by an electret, which is a dielectric with an almost constant or constant electric charge. Electret-charged polymeric materials include non-polar polymers such as polytetrafluoroethylene (PTFE) and polypropylene.

For electrification of dielectric materials, several methods are used, any of which can be used to electrify the specified filter material of the specified abrasive product, including corona discharge, heating and cooling of the specified material in the presence of a charged field, contact electrification, spraying the web with charged particles and bombarding the surface with water jets or streams water droplets. In addition, the electrification of the surface can be improved by using mixed materials. Examples of electrification methods are described in US Pat. Nos. RE 30,782 (van Turnhout et al.), RE 31,285 (van Turnhout et al.), 5,496,507 (Angadjivand et al.), 5,472,481 (Jones et al.), 4,215,682 (Kubik et al. .), 5,057,710 (Nishiura et al.) And 4,592,815 (Nakao), 5,976,208 (Rousseau et al.).

Each of these first and / or second non-woven filter materials consists of a plurality of fibers.

In some embodiments of the present invention, said non-woven filter materials comprise materials having fibers with a diameter of less than about 100 microns, and sometimes with a diameter of less than about 50 microns and even with a diameter of less than about 1 micron.

These first and (or) second non-woven filter materials can be made from a wide range of organic polymeric materials, including mixtures and compositions. Suitable filter materials include a wide range of materials available on the market. These include polyolefins, such as polypropylene, linear low density polyethylene, poly-1-butene, poly-4 (methyl-1-pentene), polytetrafluoroethylene, polychlorotrifluoroethylene; polyvinyl chloride; aromatic polyarenes such as polystyrene; polycarbonates; polyesters; and combinations of the above (including compositions or copolymers). In some embodiments of the present invention, these materials include branched alkyl radicals and their copolymers. In other embodiments of the present invention, these materials include thermoplastic fiber-forming substances (for example, polyolefins such as polyethylene, polypropylene, copolymers thereof, etc.). Other suitable materials include: thermoplastic polymers such as polylactic acid (PLA); non-thermoplastic fibers such as cellulose, district, acrylic and modified acrylic (halogen-modified acrylic); polyamide or polyimide fibers, such as those manufactured by E.I. du Pont de Nemours & Co., Wilmington, Delaware Wilmington, Delaware, USA) under the trade names "NOMEX" and "KEVLAR"; and mixtures of fibers of various polymers.

These non-woven filter media can be formed into a web using conventional non-woven fabric technologies, including, for example, aerodynamic melt spraying (melt blown), high-speed air jet ejection (spunbond), carding, aerodynamic (dry) canvas forming or wet canvas. Details regarding microfibre webs obtained by the spunbond method can be found, for example, in US Pat. Nos. 6,139,308 (Berrigan et al.) And 5,496,507 (Angadjivand et al.). Illustrative spunbond nonwoven filter media include bimodal spunbond microfiber material, such as, for example, described in US Patent Application No. 11/461136 (Brandner et al.), Filed July 31, 2006.

If necessary, the specified non-woven filter material can be characterized by a density gradient, such as, for example, a material obtained by contacting a thermoformed non-woven fabric with a hot shell. If necessary, these fibers or webs can be electrified by known methods, including, for example, the use of corona electrodes or strong electric fields. These fibers can be electrified during the formation of the fibers, before or after the formation of the fibers in the filter cloth, or after the formation of the specified filter cloth. The fibers forming the specified second filter material can be charged even after bonding with the specified first filter material. The specified second non-woven filter material may contain fibers coated with a polymeric binder or adhesive, including contact adhesives.

Specified porous mounting layer allows air to pass through it. Said porous attachment layer may include an adhesive layer, fabric, sheet material, molded body, or a combination of the above. The specified sheet material may have, for example, a loop part (loop) or a hook part (hook) of a two-element mechanical engagement system. Said porous fixing layer may include a layer of contact adhesive with an optional release liner to protect it during handling.

In some embodiments, implementation of the present invention, the specified porous mounting layer contains a non-woven, woven or knitted material with eyelets. The specified material with eyelets can be used to attach the specified abrasive product to a support plate having a complementary mating element.

Suitable materials for said porous fixing layer include both woven and non-woven materials. The woven and knitted porous fixing layer materials may have loop-forming fibers or threads included in the structure of their fabric to obtain vertical loops for engagement with hooks. Nonwoven fastener mating materials with eyelets may have eyelets formed by bonded fibers. In some nonwoven fastener mating materials with eyelets, said eyelets are formed by quilting said non-woven fabric with thread to form vertical eyelets.

Useful non-woven materials suitable for use as a porous fastening layer with eyelets include, for example, aerodynamically formed, ejected by a high-speed air stream, hydro bonded, spunbond and bonded carded webs. Said nonwoven materials can be bonded by any method known to those skilled in the art, for example, needle punch bonding, stitch bonding, hydro bonding, chemical bonding, thermal bonding and a combination of the above methods. These woven or nonwoven materials used can be made from natural fibers (e.g., wood or cotton fiber), synthetic fibers (e.g., polyester or polypropylene fiber), or from a combination of natural and synthetic fibers. In some embodiments of the present invention, said porous attachment layer is made of nylon, polyester or polypropylene fiber.

In some embodiments of the present invention, a porous loop fastening layer is selected having an open structure that does not substantially interfere with the flow of air through the web. In some embodiments of the present invention, the material of said porous mounting layer is selected, at least in part, based on the porosity of said material.

In some embodiments of the present invention, said porous attachment layer comprises hook material. The material used to form the specified material with hooks, suitable for use in these abrasive products, can be made in one of many different ways known to those skilled in the art. Some processes suitable for making hook material for the manufacture of porous abrasive fabrics include, for example, the methods described in US Pat. Nos. 5,058,247 (Thomas et al.); 4,894,060 (Nestegard); 5,679,302 (Miller et al.); and 6,579,161 (Chesley et al.).

Said hook material may be a porous material, such as, for example, the polymeric mesh material described in US Patent Application No. 2004/0170801 (Seth et al.). In other embodiments of the present invention, said hook material may be perforated to allow air to pass through it. Holes in said hook material may be formed using any methods known to those skilled in the art. For example, these holes can be made in a sheet of material with hooks using, for example, a stamp, a laser, or other perforating tools known to those skilled in the art. In other embodiments of the present invention, said hook material may be made with holes.

The specified porous mounting layer of the specified abrasive product is attached to the specified filter material in a manner that does not impede the passage of air from the specified filter material. In some embodiments of the present invention, said porous mounting layer of said abrasive article is attached to said filter material in a manner that does not substantially impede the passage of air from said filter material. The degree of air flow through said porous fixing layer can be limited, at least in part, by introducing an adhesive between said porous fixing layer containing sheet material and said filtering material. The degree of restriction can be minimized by intermittent application of adhesive between the specified sheet material of the specified porous mounting layer and the specified filter material, for example, in the form of separate sections of the adhesive (for example, droplet spraying or extrusion with insufficient supply) or separate lines of adhesive (for example, swirl spraying of hot melt or using a coating system with a figure roller).

Examples of possible adhesives include both contact adhesives and non-contact adhesives. Contact adhesives are usually sticky at room temperature and can stick to the surface as a result of a light finger touch, and non-contact adhesives contain a solvent or radiation-activated adhesive systems, or require heating. Examples of suitable adhesives include those based on general polyacrylate compositions; polyvinyl ether; diene-containing rubbers such as natural rubber, polyisoprene and polyisobutylene; polychloroprene, butyl rubber; butadiene-acrylonitrile polymers; thermoplastic elastomers; block copolymers such as styrene-isoprene and styrene-isoprene-styrene block copolymers, ethylene-propylene-diene polymers and styrene-butadiene polymers; poly (alpha olefins; amorphous polyolefins; silicone; ethylene-containing copolymers such as ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer and ethylene-ethyl methacrylate copolymer; polyurethanes; polyamides; polyesters; epoxides; poly (vinylpyrrolidone and vinyl copolymers above) In addition, these adhesives may contain additives such as tackifiers, plasticizers, fillers, antioxidants, stabilizers, pigments, diffusers, hardeners and solvents.

These various layers of said abrasive product may be bonded to each other using any suitable bonding method, such as, for example, using glue, contact adhesive, hot melt adhesive, spray adhesive, heat bonding, needle-puncture bonding, stitch bonding and ultrasonic welding. In some embodiments of the present invention, said layers are adhered to each other by applying on one side of said porous abrasive a spray adhesive, such as, for example, “3M BRAND SUPER 77 ADHESIVE” manufactured by 3M Company, St. Paul, Minnesota (Saint Paul, Minnesota, USA). In other embodiments of the present invention, a hot melt adhesive is applied to one side of the layer using a hot melt glue gun or extruder with a comb insert. In some other embodiments of the present invention, a finished adhesive mesh is placed between the bonded layers.

If necessary, to prevent lateral emission of particles not retained by said abrasive product, a sealant is usually applied to most (if not all) of the outer edge of said abrasive product. Examples of sealing methods include sealing, taping, latex coating, coating and the use of sealants (e.g., latex or silicone).

Abrasive products according to the subject of the present invention are generally useful for collecting particles during abrasive processing, and in some cases are capable of holding large amounts of particles at high delivery rates. These abrasive products are suitable for use with any device adapted to use such products. Examples include arbitrary surface grinders, double-action grinders and disk machines with or without vacuum applied to said porous mounting layer and / or second non-woven filter material of said abrasive product.

Although this does not follow from any particular theory, it is believed that in the case of abrasive articles that are the subject of the present invention, several filter components can function in such a way that an auxiliary component (e.g., the first non-woven filter material) can contribute , second non-woven filter material), which can compensate for damage or lack of effectiveness of the specified first component, while maintaining the total efficiency at a high first level and improving the performance to a level corresponding to the performance of said abrasive with which these components are used.

Accordingly, in some embodiments of the present invention, at least a portion of the abrasive article (eg, a representative perforated area) that is the subject of the present invention (in an unused state) exhibits a pressure drop in the range of 0.2 to 20 mm water column according to the Differential Pressure Measurement Test (see below). For example, at least a portion of the abrasive article of the present invention (in an unused state) exhibits, according to the Differential Pressure Measurement Test, a pressure drop in the range of 1 to 15 mm water column or even 4 to 10 mm water column. The specified Pressure Differential Measurement Test is performed as follows. The pressure drop along the thickness of the specified abrasive product is determined using a filter test device consisting of a pair of cylinders of the same inner diameter, mounted in series so that the length of the cylinders is oriented vertically and that the air passes through these cylinders with a frontal velocity of 5.2 cm /from. Each cylinder is equipped with a pressure sensor to measure the pressure inside the cylinders. The adjacent ends of the upper and lower cylinders are hermetically connected through the specified abrasive product. The test specified abrasive product is tightly clamped between the cylinders so as to prevent lateral leakage, and the outer abrasive surface of the specified abrasive product is perpendicular to the direction of air flow and facing it. The difference in air pressure between the first and second cylinders is recorded as the pressure drop on the specified abrasive product.

All patents, patent applications, and publications cited herein are incorporated herein by reference in their entirety, as if they were individually incorporated.

The advantages and other embodiments of the present invention are further illustrated by the following examples, however, the specific materials and their quantities indicated in these examples, as well as other conditions and details, should not be construed as limiting the present invention.

Unless otherwise indicated, all shares, percentages, ratio, etc. in the present examples and the rest of the description are by weight.

EXAMPLES

The following abbreviations are used in the examples below.

MATERIALS Designation DESCRIPTION AM1 Non-porous coated abrasive material available on the market under the trade name "360L GRADE P800", manufactured by 3M Company; St. Paul, Minnesota (St. Paul, Minnesota, USA). AM2 AM1, 13-millimeter (330 μm) laminated tape, laser-cut laminate, 5-inch (12.7 cm) discs, with laser hole distribution according to Procedure 2 (see below). AM3 6 ”(15.2 cm) coated porous abrasive material commercially available under the trade designation“ NORTON MULTI-AIR, P800, ”manufactured by Norton, Worcester, Massachusetts (Worcester, Massachusetts, USA), from which it is stamped 5 inch (12.7 cm) disks were cut down. AM4 Porous mesh abrasive product of category P320 with integral fastening substrate with eyelets, commercially available under the trade designation "ABRANET P320", manufactured by KWH Mirka Ltd., Jeppo, Finland (Yppo, Finland). AM5 A porous abrasive product of the ANSI Grade 500 grade, commercially available under the trade name "3M 281 FABRICUT", manufactured by 3M Company, from which 5 inch (12.7 cm) disks are cut by stamp. AM6 The repetition of the mesh abrasive described in Example 3, from the publication of US patent application No. 2006/0148390 A1 (Woo and others). FM1 Non-woven polyester backing, available on the market under the trade name "3M CARPET BONNET PAD WHITe", manufactured by 3M Company, from which 5 inch (12.7 cm) disks are cut by stamp. FM2 Electret staple fiber canvas, base weight 150 g / m ² , available on the market under the trade name "FILTRETE G150", manufactured by 3M Company, from which 5 inch (12.7 cm) disks are cut by stamp. FM3 FM1 with lip sealed with a commercially available sealant as described in Procedure 1 (below). FM4 Non-woven filter media prepared as described in Procedure 6 (see below). FM5 Canvas made of bimodal spunbond microfiber (BMF) electret polypropylene, a base weight of 260 g / m ² , a thickness of 3.6 mm, prepared generally in accordance with the procedure of Example 1. in patent application US No. 11/461136 (Brandner and others), filed July 31, 2006 FM6 Canvas made of bimodal spunbond microfibre (BMF) electret polypropylene, base weight 94 g / m ² , 0.9 mm thick, prepared in general in accordance with the procedure of Example 1. in patent application US No. 11/461136 (Brandner and others), filed July 31, 2006 AT1 A fastening web with eyelets available on the market under the trade name "70 G / M2 TRICOT DAYTONA BRUSHED NYLON LOOP FABRIC", manufactured by Sitip SpA, Cene, Italy (Chen, Italy). FIB1 Polyester staple fiber commercially available from Fiber Innovation Technology Inc. Johnson City, Tennessee (Johnson City, Tennessee, USA) under the trade name "T-240 SORET / PET". FIB2 Polyester staple fiber commercially available from KoSa, Salisbury, North Carolina (Salisbury, Sev. Carolina, USA) under the trade name "Type 224", 15 denier, 2 inches long (51 mm).

Procedure 1. Sealing the edge of the filter material

The edge of the filter media disc 1, FM1, was sealed by applying an even, continuous roll of silicone-acrylic sealant manufactured by DAP Products, Inc., Baltimore, Maryland (Bartimore, Maryland, USA) under the trade name "DAP ALEX PLUS" , on the outer edge (bordering a circle) of the disk. The sealing material was pressed into the edge of the filter material with a spatula. The sealing material was allowed to dry for at least 8 hours. FM1 sealed in this way was designated as FM3.

Procedure 2. Lamination of the tape carrier on abrasive material and laser perforation

The abrasive sheet 1, AM1, was laminated onto a similarly sized sheet of double-sided carrier tape manufactured by 3M Company under the trade name "3M 964 13 MIL TRANSFER TAPE" using the following procedure. One side of the strip gasket was removed, and the side of the sheet AM1, opposite the outer abrasive surface, was manually pressed to the exposed contact adhesive of the tape. The laminated abrasive was perforated by a laser according to pattern 400 shown in FIG. 4. Laser-punched and cut out of this layered structure discs with a diameter of 5 inches (12.7 cm) were designated as AM2.

Procedure 3. Attaching Filter Material or Abrasive to ATI

A contactless adhesive commercially available from 3M Company under the trade name "SUPER 77 SPRAY ADHESIVE" was applied to the non-looped side of an approximately 6-inch (15.2 cm) square sheet of ATI and allowed to dry for about 30 seconds at 25 ° C.

The dry weight of the adhesive was approximately 12 mg / cm ² . The round surface of the filter material FM1, FM2 or FM3, or the abrasive material AM5 or AM6 was laminated onto the adhesive surface AT1. The excess material AT1, protruding along the edges of the structure, was cut with scissors, and a round, essentially having the same dimensions, multilayer structure was obtained.

Procedure 4. Attaching the filter material to AM2

The AM2 carrier strip gasket was removed exposing the sticky contact adhesive of the tape. The corresponding round disc of the filter material, FM1 or FM3, was combined and manually laminated to the adhesive so that the layer AM2 and the layer of filter material had essentially the same measurements.

In some cases, FM1 and FM3 were pre-laminated to FM2, as indicated below. In these cases, the exposed round surface of FM1 or FM3, i.e. the side opposite the side attached to FM2 was laminated to AM2.

In the case where AM2 was attached to the FM4 / FM5 filter material fastened by needle-piercing, AM2 was attached to the exposed round surface of FM4, forming essentially identical layers.

Procedure 5. Attaching FM1 or FM3 to FM2

Contact adhesive, commercially available from 3M Company under the trade name "SUPER 77 SPRAY ADHESIVE", was applied to the circular surface of the filter media FM1 and FM3 and left to dry for about 30 seconds at 25 ° C. The dry weight of the adhesive was approximately 12 mg / cm ² . Then, two adhesive-coated round surfaces were combined and laminated one on top of the other. The resulting structure was left to dry, forming, in essence, a two-layer structure having identical dimensions.

Procedure 6. Production of FM4

FM4 was obtained from a mixture of 90/10 parts by weight of FIB1 and FIB2. The base weight of this mixture was approximately 155 grams per 24 square meters. inches (648 g / m ² ), the thickness was approximately 5 inches (12 cm). For molding FM4 from said mixture of fibers, an aerodynamic canvas forming machine commercially available from Rando Machine Corporation, Macedon, New York (Macedon, NY, USA) under the trade name "RANDO WEBBER" was used (under normal conditions).

Procedure 7. Attaching FM4 to FM5

After leaving the Rando Webber in Procedure 6, FM4 was placed on FM5 and the two layers were bonded to each other by passing through a needle punch machine commercially available from STP Impianti Spa, Milan, Italy under the trade name " AUTOMATEX ", at a speed of 1.52 mm / min. The speed of the needle punching machine was 185 working strokes / min, the penetration depth from the top was 15 mm, the piercing density was 8.4 piercing / cm ² . We used needles of the F20 9-37-9K 15X20x2.5 type, commercially available from Foster Needle Co., Manitowoc, Wisconsin (Manitowoc, Wisconsin, USA). The final base weight of needle-punched filter material FM5 / FM6 was approximately 855 g / m ² , and the thickness was approximately 5.2 mm. Specified combined non-woven structure passed through a convection oven for 2 minutes at 129 ° C, where FIB1 connected the entire structure together. The final structure was allowed to cool to 25 ° C.

Using the procedures described above, many multilayer abrasive-filter discs were prepared, as indicated in Table 1, Table 2, and Table 3. Duplicate examples (i.e., repeats of the same construction) are indicated by a number followed by a letter (for example, Example 1a, Example 1b and Example 1c). Duplicate comparative examples are indicated by a letter followed by a number (e.g., Comparative Example A1, Comparative Example A2, and Comparative Example A3). The various properties of some materials are given in table 4.

For any given specific example, the components (for example, porous abrasive material, filter material and porous mounting layer) that are adjacent to each other in the tables are adjacent in real abrasive products. It will be apparent to those skilled in the art that the sequence in which these layers are joined together to form a multilayer abrasive disc often does not matter much if the desired final construction is obtained.

In addition, it is understood that if two or more different filter materials are used in the construction of a multilayer abrasive filter disk, the order in which they are placed relative to the specified abrasive material can affect the performance of the specified abrasive product. In this sense, different filter media in a multilayer construction may not be interchangeable. This situation includes the situation when a single filter material is used, characterized by a gradient of filtering abilities (for example, largely inhomogeneous in the direction of passage of the filtered particles.

Test methods

Sanding Test Method 1

A 5.0 inch (12.7 cm) diameter abrasive disk was weighed and attached to a foam backing plate with a diameter of 5.0 inches (12.7 cm) and 3/8 inch (0.95 cm) thick with 40 holes, commercially available from 3M Company under the trade name "3M HOOKIT BACKUP PAD, # 20206 ". The specified base plate and disc assembly were then mounted on a double-action surface grinder, 5-inch (12.7 cm) diameter for semi-rough machining, model 21033, commercially available from Dynabrade Corp., Clarence, New York (Clarence, NY ) The abrasive side of the indicated disk was manually contacted with a pre-weighed reinforced plastic fiberglass panel with an external coating measuring 18 inches by 30 inches (46 cm × 76 cm) obtained from White Bear Boat Works, White Bear Lake, Minnesota (White) Bear Lake, Minnesota, USA). Sanding machine was operated at a pressure in the air line of 90 fnl. / ^In2 (620 kPa) and a clamping force of 10 lb. power (44 N); performed 2 treatment cycles of 75 seconds each. An angle of 0 ° to the surface of the workpiece was used. Each cycle consisted of 24 overlapping transverse passages with a total length of 504 inches (12.8 m) at a tool speed of 6.7 inches / s (17 cm / s) relative to the surface of the panel, which led to an even cleaning of the test panel area. After the first treatment cycle, the test panel was cleaned of visible dust by blowing with compressed air to the top of the cleaned panel. The disc was removed from the base plate, and the panel and disc were weighed. The abrasive was then reinstalled on the backing plate and the 75 second stripping cycle was repeated using the same test panel. The test panel was again cleaned of visible dust by blowing with compressed air the top of the cleaned panel. The abrasive disc was removed from the base plate, and the panel and disc were weighed. Data after the 2nd cleaning cycle is given; the total cleaning time is 150 s.

For each sample tested, the following measurements were made; the results presented in table 1 and table 2 are averaged over two tested samples for each example.

"Chips": weight, in grams, of material removed from the plastic panel;

"Retained": weight, in grams, of material collected in the test disc; and

DE%: Holding / Chip ratio multiplied by 100.

Grinding Test Method 2

The 5.0 inch (12.7 cm) diameter abrasive filter disk was weighed, attached to the base plate, and the base plate and complete disk were then mounted on a surface grinder as described in Sanding Test Method 1. The abrasive side of the specified disk was manually contacted with pre-weighed reinforced plastic fiberglass panel with an external coating measuring 18 inches by 30 inches (45.7 cm × 76 cm), obtained from White Bear Boat Works, White Bear Lake, Minnesota (White Bear Lake, Minnesota, USA). Sanding machine was operated at a pressure in the air line, equal to 90 lb / ⁱⁿ² (620 kPa).; 6 processing cycles of 25 seconds each were performed. An angle of 0 ° to the surface of the workpiece was used. After the first 3 treatment cycles, the test panel was cleaned of visible dust by blowing with compressed air to the top of the cleaned panel. The disc was removed from the base plate, and the panel and disc were weighed. Then the abrasive was again mounted on the base plate and the final 3 cleaning cycles were carried out using the same test panel. The test panel was again cleaned of visible dust by blowing with compressed air the top of the cleaned panel. The abrasive disc was removed from the base plate, and the panel and disc were weighed. Data is provided after the 6th stripping cycle; the total stripping time is 150 s.

For each sample tested, the following measurements were made; the results presented in table 1 and table 2 are averaged over two tested samples for each example.

"Chips": weight, in grams, of material removed from the plastic panel;

"Retained": weight, in grams, of material collected in the test disc; and

DE%: Holding / Chip ratio multiplied by 100.

Method for measuring the quality of surface treatment

The resulting surface roughness of the trimmed test panels was determined using a profilometer commercially available from Mahr Corporation, Cincinnati, Ohio (Cincinnati, Ohio, USA) under the trade name "PERTHOMETER MODEL M4P-130589". The surface roughness values were measured in three cleaned areas of the test panel after each completed 150-second grinding test. For each measurement, the value of Rz (also known as Rtm) was recorded, which is the average value of the maximum distances from the protrusion to the cavity of the profile.

Modified Differential Pressure Test

The pressure differential test described herein was performed using a filter test apparatus consisting of a pair of cylinders with an inner diameter of 4.5 inches (11.4 cm) at an air flow rate of 32 liters / min. Pressure sensors of the model "MKS BARATRON PRESSURE TRANSDUCER, 398HD-00010SP12" (range 10 Torr (1.33 kPa)) were obtained from MKS Instruments, Wilmington, Massachusetts (Wilmington, Massachusetts, USA).

As a cleaning procedure to obtain the data presented in Table 1, the grinding test method 1 was used. As a cleaning procedure to obtain the data presented in table 2, the grinding test method 2 was used.

Modified Pressure Drop Measurement Tests were not conducted for all examples. The results of the modified Pressure Differential Measurement Test for some of the examples given in Tables 1 and 2 are shown in Table 3 along with data related to additional comparative examples.

Tests for measuring the differential pressure were carried out for abrasive products before performing any grinding operation according to Test Method 1 by grinding or Test Method 2 by grinding, except as indicated in Table 3.

TABLE 1 ABRASIVE
NEW ELEMENT FIRST FILTER
GENERAL MATERIAL SECOND FILTERING MATERIAL POROUS FASTENERS
NEW LAYER Shavings, g Withheld, g DE,% Rz, (μm) Example 1a AM2 FM1 FM2 none 2.44 1.81 74 1.2 Example 2a AM2 FM3 FM2 none 2.30 1.49 65 1.4 Example 3a AM2 FM1 FM2 AT1 2.41 1.89 78 1.3 Example 4a AM2 FM3 FM2 AT1 2.49 1.86 75 1.4 Example 5 AM2 FM4 FM5 none 2.42 2.34 97 1.4 Comparative Example A1 AMZ no no no 4.38 0.09 2 1.9 Reference Example A4 AMZ no no no 3.70 0.79 21 1.9

TABLE 2 ABRASIVE
NEW ELEMENT FIRST FILTER MATERIAL SECOND FILTERING MATERIAL POROUS FASTENING LAYER Shavings, g Holding
but g DE,% Rz, (μm) Example 1b AM2 FM1 FM2 no 2.95 2.71 92 1.5 Example 2b AM2 FM3 FM2 no 3.24 2.97 92 1.3 Example 3b AM2 FM1 FM2 AT1 3.04 2.83 93 1.5 Example 4b AM2 FM3 FM2 AT1 2.79 2.58 92 1.5 Example 6 AM2 FM1 FM6 AT1 5.64 4.38 78 1.6 Example 7 AM2 FM3 FM6 AT1 4.51 3.86 86 1.7 Comparative Example A2 AM3 no no no 3.57 0.07 2 2.1 Comparative Example A3 AM3 no no no 6.80 0.07 one 2.2

Examples 1b, 2b, 3b, 4b and Comparative Example A2 were performed using the same glass fiber reinforced plastic panel with an external gel coating. Examples 6, 7 and Comparative Example A3 were performed using the same reinforced plastic fiberglass panel with an external gel coating, but this plate was different than in the previous case. Example 5 and Comparative Example A4 were performed on another separate plate. Changing the panels could lead to variability in the chip measurement results.

TABLE 3 ABRASIVE ELEMENT FIRST FILTER MATERIAL SECOND FILTERING MATERIAL POROUS FASTENING LAYER AR (MM N ₂ O) Example 1c AM2 FM1 FM2 no 1.25 Example 3c AM2 FM3 FM2 AT1 1.72 Example 1b * AM2 FM1 FM2 no 5.00 Example 3b * AM2 FM1 FM2 AT1 9.13 Example 5 AM2 FM4 FM5 no 2.04 Example 6 AM2 FM1 FM6 AT1 2.09 Example 7 AM2 FM3 FM6 AT1 2.33 Comparative Example A3 AM3 no no no 0.06 Comparative Example B AM4 no no no 0.03 Comparative Example C AM5 no no no 0.03 Comparative Example D AM5 no no AT1 0.09 Comparative Example E AM6 no no no 0.03 Comparative Example F AM6 no no AT1 0.10 Comparative Example G AM2 FM1 no no 0.38 Comparative Example H AM2 FM1 no ATI 0.71 * The measurements for examples 1b and 3b in table 3 (above) were made after completion of the Test by grinding method 2.

TABLE 4 MATERIAL BASIS WEIGHT (g / m ² ) THICKNESS (CM) VOLUME DENSITY (g / cm ³ ) FIBER DIAMETER (micrometers) FM1 482 (461-503) 0.706 (0.67-0.74) 0.068 thirty FM2 150 0.25 0.060 from 12 × 12 to 12 × 25 FM5 260 0.36 0.072 29 average (bimodal) FM6 94 0.087 0.107 22 average (bimodal) AT1 70 0.045 0.156 not determined

Without deviating from the scope and essence of the present invention, those skilled in the art can make various modifications and changes to it, and it should be understood that the present invention is not limited to the illustrative embodiments set forth herein.

Claims (18)

1. An abrasive product containing:
a porous abrasive element having: an abrasive layer adjacent to and attached to a first surface of a substrate, consisting of a plurality of abrasive particles attached to said first surface of said substrate with at least one binder, said abrasive layer having an external abrasive surface and said substrate having a second a surface opposite said first surface of said substrate, and from said external abrasive surface to said second surface of said substrate many holes go through
a first non-woven filter material having a first surface and a second surface opposite to said first surface, said first surface of said first non-woven filter material adhering to and attached to said second surface of said substrate, wherein said first non-woven filter material consists of a plurality of fibers, and
a second non-woven filter material having a first surface and a second surface opposite to said first surface, wherein said first surface of said second non-woven filter material is adjacent and attached to said second surface of said first non-woven filter material, wherein said second non-woven filter material consists of a plurality of fibers ,
moreover, these numerous holes are combined with the specified first non-woven filter material to ensure the passage of particles from the specified external abrasive surface to the specified second filter material, while in an unused state, at least part of the specified abrasive product provides a pressure drop in the range from 0.2 to 20 mm of water according to the results of tests for measuring differential pressure. 2. The abrasive product according to claim 1, characterized in that said porous abrasive element comprises openings with a coated abrasive material. 3. The abrasive product according to claim 1, characterized in that it has a porous mounting layer adjacent and attached to the specified second surface of the specified second non-woven filter material. 4. The abrasive product according to claim 1, characterized in that at least one of these first or second non-woven filter material has an outer edge, most of which is sealed. 5. The method of abrasive treatment of the surface of the part, including bringing the surface of the part into contact with the abrasive product according to claim 1 and the relative movement of the specified abrasive product and the specified surface for mechanical change of the specified surface. 6. A method of manufacturing an abrasive product, including:
the use of a porous abrasive element having: an abrasive layer adjacent to and attached to a first surface of a substrate and consisting of a plurality of abrasive particles attached to said first surface of said substrate with at least one binder, said abrasive layer having an external abrasive surface, and said substrate has a second surface opposite the specified first surface of the specified substrate, and from the specified external abrasive surface to the specified second surface said substrate passes a plurality of apertures,
the use of a first non-woven filter material, wherein said first non-woven filter material has a first surface and a second surface opposite to said first surface, and contains a plurality of fibers, said first surface of said first non-woven filter material adhering to said second surface of said substrate,
the use of a second non-woven filter material, said second non-woven filter material having a first surface and a second surface opposite to said first surface, wherein said second non-woven filter material contains a plurality of fibers, and said first surface of said second non-woven filter material is adjacent to said second surface of said first filter material
attaching said first nonwoven filter material to said second surface of said substrate; and
attaching said second non-woven filter material to said first non-woven filter material,
however, numerous openings are combined with said first non-woven filter material to allow particles to pass from said external abrasive surface to said second filter material, and in an unused state, at least a portion of said abrasive article provides a pressure drop in the range from 0.2 to 20 mm of water column according to the results of tests for measuring differential pressure. 7. A method of manufacturing an abrasive product according to claim 6, characterized in that said porous abrasive element contains coated abrasive material with openings. 8. A method of manufacturing an abrasive product according to claim 6, characterized in that it comprises sealing most of the outer edge of at least one of the first or second non-woven filter material. 9. A method of manufacturing an abrasive product according to claim 6, characterized in that it includes attaching a porous mounting layer to the specified second non-woven filter material. 10. An abrasive product containing:
a porous abrasive element having an abrasive layer adjacent to and attached to a first surface of a substrate and consisting of a plurality of abrasive particles attached to said first surface of said substrate by at least one binder, said abrasive layer having an external abrasive surface and said substrate having a second surface opposite to the specified first surface of the specified substrate, and from the specified external abrasive surface to the specified second surface of the specified substrate there are many holes, the first non-woven filter material having a first surface and a second surface opposite to the specified first surface, and the specified first surface of the specified first non-woven filter material is adjacent and attached to the specified second surface of the specified substrate, while the specified first non-woven filter material consists of many fibers and has a thickness of 1 to 25 mm and a density of 0.04 to 0.5 grams per cubic centimeter, and the second non-woven filter material, I have the first surface and the second surface opposite the specified first surface, wherein said first surface of said second non-woven filter material is adjacent and attached to said second surface of said first filter material, wherein said second non-woven filter material consists of a plurality of fibers and has a thickness of 0, 5 to 15 mm and bulk density from 0.04 to 0.5 grams per cubic centimeter,
wherein said numerous openings are combined with said first non-woven filter material to allow particles to pass from said external abrasive surface to said second filter material. 11. The abrasive product of claim 10, characterized in that the porous abrasive element contains openings with a coated abrasive material. 12. The abrasive product of claim 10, characterized in that it has a porous mounting layer adjacent and attached to the specified second surface of the specified second non-woven filter material. 13. The abrasive product of claim 10, characterized in that at least one of these first or second non-woven filter material has an outer edge, most of which is sealed. 14. The method of abrasive processing of the surface of the part, including bringing the surface of the part into contact with the abrasive product of claim 10 and the relative movement of the specified abrasive product and the specified surface for mechanical change of the specified surface. 15. A method of manufacturing an abrasive product, including:
the use of a porous abrasive element having an abrasive layer adjacent to and attached to a first surface of a substrate and consisting of a plurality of abrasive particles attached to said first surface of said substrate with at least one binder, said abrasive layer having an external abrasive surface and said substrate having a second a surface opposite the specified first surface of the specified substrate, and from the specified external abrasive surface to the specified second surface the specified substrate passes many holes,
the use of a first non-woven filter material having a first surface and a second surface opposite the specified first surface, wherein said first surface of said first non-woven filter material is adjacent to said second surface of said substrate, wherein said first non-woven filter material consists of a plurality of fibers and has a thickness of 0.5 to 15 mm and bulk density from 0.04 to 0.5 grams per cubic centimeter,
the use of a second non-woven filter material having a first surface and a second surface opposite said first surface, wherein said first surface of said second non-woven filter material is adjacent to said second surface of said first non-woven filter material, wherein said second non-woven filter material contains a plurality of fibers and has thickness from 0.5 to 15 mm and bulk density from 0.04 to 0.5 grams per cubic centimeter,
attaching said first nonwoven filter material to said second surface of said substrate; and
attaching said second non-woven filter material to said first filter material, wherein said multiple openings are combined with said first non-woven filter material to allow particles to pass from said external abrasive surface to said second filter material. 16. A method of manufacturing an abrasive product according to item 15, wherein the specified porous abrasive element contains a coated abrasive material with openings. 17. A method of manufacturing an abrasive product according to clause 15, characterized in that it comprises sealing most of the outer edge of at least one of these first or second non-woven filter material. 18. The method of manufacturing an abrasive product according to clause 15, characterized in that it includes attaching a porous mounting layer to the specified second non-woven filter material.

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