TW202104519A - Abrasive articles having improved performance - Google Patents

Abstract

Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a heat-activated water-forming inorganic component dispersed through the non-woven web.

Description

Abrasive articles with improved performance

Non-woven abrasive articles generally have a non-woven web (for example, a fluffy open fiber web), abrasive particles, and a binder material (usually called "Binder").

Various embodiments of the present disclosure relate to abrasive articles. The abrasive article includes a nonwoven mesh. The nonwoven web includes a fiber or filament component. The nonwoven web further includes a first major surface and a second major surface. A thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles that are dispersed through at least a portion of the nonwoven web. The abrasive article further includes a heat-activated water-forming inorganic component passed through the nonwoven web.

Various embodiments of the present disclosure relate to abrasive articles. The abrasive article includes a nonwoven mesh. The nonwoven web includes a fiber or filament component. The nonwoven web further includes a first major surface and a second major surface. A thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped Shaped abrasive particles, the plurality of shaped abrasive particles are dispersed through at least a part of the nonwoven web. The abrasive article further includes a hydrated aluminum compound dispersed through the nonwoven web.

Various embodiments of the present disclosure relate to abrasive articles. The abrasive article includes a nonwoven mesh. The nonwoven web includes a fiber or filament component. The nonwoven web further includes a first major surface and a second major surface. A thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles that are dispersed through at least a portion of the nonwoven web. The abrasive article further includes a hydrated aluminum compound dispersed through the nonwoven web. About 5% to about 70% of the plurality of shaped abrasive particles include a tip that is oriented in a direction substantially perpendicular to a line traveling through the first major surface and the second major surface.

Various embodiments of the present disclosure relate to abrasive articles. The abrasive article includes a nonwoven mesh. The nonwoven web includes a fiber or filament component. The nonwoven web further includes a first major surface and a second major surface. A thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles that are dispersed through at least a portion of the nonwoven web. The abrasive article further includes a hydrated aluminum compound dispersed through the nonwoven web. A portion of the plurality of shaped abrasive particles includes a surface that is oriented substantially perpendicular to a direction that travels through a line of the first major surface and the second major surface, and the portion is in the plurality of surfaces. The shaped abrasive particles range from about 5% to about 70%.

According to various embodiments of the present disclosure, a slurry includes a plurality of shaped abrasive particles. The slurry further includes a thermally activated water forming inorganic component. The slurry further includes a solvent, lubricant, and adhesive.

According to various embodiments of the present disclosure, a method of manufacturing an abrasive article is described. The abrasive article includes a nonwoven mesh. The nonwoven web includes a fiber or filament component. The nonwoven web further includes a first major surface and a second major surface. A thickness of the nonwoven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles that are dispersed through at least a portion of the nonwoven web. The abrasive article further includes a heat-activated water-forming inorganic component passed through the nonwoven web. The method includes forming a nonwoven web of one of the fibers or filaments. The method further includes perforating the net. The method further includes applying the abrasive particles and a binder to the perforated web. The method further includes curing the adhesive to provide the abrasive article.

10: Abrasive items

12: Non-woven mesh/non-woven abrasive mesh/net

14: The first major surface

16: second major surface

18: Fiber component

20: Fiber

22: Abrasive particles/particles

22A: Tetrahedral shaped abrasive particles

22B: Tetrahedral shaped abrasive particles

22C: Tetrahedral shaped abrasive particles

22D: Tetrahedral shaped abrasive particles

22E: Tetrahedral shaped abrasive particles

24: Adhesive

30: Triangle column base/base

32: Triangle column top/top

34A: side wall

34B: Sidewall

34C: Sidewall

36A: Tip

36B: Tip

36C: Tip

40E: Noodles

42A: Noodles

42B: Noodles

42C: Noodles

42D: Noodles

44A: Noodles

44B: Noodles

44C: Noodles

44D: Noodles

44E: Noodles

46A: Noodles

46B: Noodles

46C: Noodles

46D: Noodles

46E: Noodles

48A: Noodles

48B: Noodles

48C: Noodles

48D: Noodles

48E: Noodles

50A: Edge

50B: Edge

50C: Edge

50D: Edge

50E: Edge

52A: Edge

52B: Edge

52C: Edge

52D: Edge

52E: Edge

54A: Edge

54B: Edge

54C: Edge

54D: Edge

54E: Edge

56A: Edge

56B: Edge

56C: Edge

56D: Edge

56E: Edge

58A: Edge

58B: Edge

58C: Edge

58D: Edge

58E: Edge

60A: Edge

60B: Edge

60C: Edge

60D: Edge

60E: Edge

62A: Tip

62B: Tip

62C: Tip

62D: Tip

62E: Tip

64A: tip

64B: tip

64C: tip

64D: tip

64E: tip

66A: Tip

66B: Tip

66C: Tip

66D: tip

66E: tip

68A: Tip

68B: Tip

68C: Tip

68D: tip

68E: tip

The drawings generally illustrate various embodiments discussed in this document by way of example rather than limitation.

Figure 1 is a perspective view of an abrasive article.

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

3A to 3D are schematic diagrams of shaped abrasive particles having a flat trigonal shape according to various embodiments.

4A to 4E are schematic diagrams of tetrahedral shaped abrasive particles according to various embodiments.

Figure 5 is a graph showing the penetration depth of shaped abrasive particles in a nonwoven web according to various embodiments.

Figure 6 is a graph showing the penetration depth of shaped abrasive particles in a nonwoven web according to various embodiments.

Figure 7 is a graph showing the penetration depth of shaped abrasive particles in a nonwoven web according to various embodiments.

The specific embodiments of the disclosed subject matter will now be described in detail, and some examples thereof are shown in the drawings. Although the disclosed subject matter will be described in conjunction with the listed patent application scope, it will be understood that the exemplified subject matter is not intended to limit the patent application scope to the disclosed subject matter.

Throughout this document, the values expressed in the range format should be interpreted in a flexible manner, so that not only the values stated as the upper and lower limits of the range are included, but also all individual values or sub-ranges included in the range, as if explicitly stated Describe the values and sub-ranges. For example, "about 0.1% to about 5% (about 0.1% to about 5%)" or "about 0.1% to 5% (about 0.1% to 5%)" should be interpreted as including more than 0.1% to about 5% , Also includes individual values within the indicated range (for example, 1%, 2%, 3%, and 4%) and sub-ranges (for example, 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) . The statement "about X to Y" means the same as "about X to about Y" unless otherwise specified. Similarly, the statement "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z". , Unless otherwise specified.

In this document, the term "一 (a,an)" or "the (the)" is used to include one or more than one, unless the context clearly dictates otherwise. The term "or" is used to refer to the non-exclusive "or" unless otherwise specified. The statement "at least one of A and B" has the same meaning as "A, B, or A and B (A, B, or A and B)". In addition, it should be understood that the words or terms used in this article and not otherwise defined are only for illustrative purposes and will not cause limitation. Any use of paragraph headings is intended to assist the reading of this document and is not construed as limiting; information related to paragraph headings may appear inside or outside the specific paragraph.

In the method described herein, the actions can be performed in any order without departing from the principle of this disclosure, unless the time or operation sequence is explicitly stated. In addition, the specified actions can be performed simultaneously, unless there is an explicit patent application language that states that these actions are performed separately. For example, the requested X action and the requested Y action can be performed simultaneously in a single operation, and therefore the obtained method will fall within the context of the requested method.

The term "about" used in this article may allow a certain degree of variation in the value or range, such as within 10%, 5%, or 1% of the stated value or the upper and lower limits of the stated range , And exactly include the stated value or range.

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

As used herein, "shaped abrasive particle" means an abrasive particle having a predetermined or non-random shape. A process for manufacturing shaped abrasive particles (such as shaped ceramic abrasive particles) includes shaping precursor ceramic abrasive particles in a mold having a predetermined shape to produce ceramic shaped abrasive particles. The ceramic shaped abrasive particles formed in a mold are a species in the genus of shaped ceramic abrasive particles. Other procedures for producing shaped ceramic abrasive particles of other species include extruding precursor ceramic abrasive particles through orifices having a predetermined shape, printing precursor ceramic abrasive particles through openings in a printing screen with a predetermined shape, or combining precursor ceramic abrasive particles. The abrasive particles are embossed into a predetermined shape or pattern. In other examples, shaped ceramic abrasive particles can be cut from the sheet into individual particles. Examples of suitable cutting methods include mechanical cutting, laser cutting, or water jet cutting. Non-limiting examples of shaped ceramic abrasive particles include shaped abrasive particles, such as triangular plates, or elongated ceramic rods/filaments. The shaped ceramic abrasive particles are substantially homogeneous or substantially uniform, without the need to use binders (such as organic or inorganic binders) that combine smaller abrasive particles into a cohesive structure to maintain their sintered shape, and eliminate the need for Abrasive particles obtained by a crushing or pulverizing process, which produces abrasive particles of random size and shape. In many embodiments, the shaped ceramic abrasive particles comprise a homogeneous structure of sintered alpha alumina, or consist essentially of sintered alpha alumina.

FIG. 1 is a perspective view of an abrasive article 10. Figure 2 is a cross-sectional view of the abrasive article of Figure 1 taken along section line 2-2. Figures 1 and 2 show substantially the same components and are discussed at the same time. As shown in FIGS. 1 and 2, the abrasive article 10 includes a nonwoven web 12. The nonwoven web 12 includes a first major surface 14 and an opposite second major surface 16. The first main surface 14 and the Each of the two main surfaces 16 has an irregular or substantially non-flat profile, but in other embodiments, the surface may be flat. The nonwoven web 12 includes a fiber component 18 that includes individual fibers 20. The non-woven web 12 further includes abrasive particles 22 dispersed throughout the non-woven web 12; a binder 24 adheres the abrasive particles to the individual fibers 20.

The fiber component 18 can be in the range of from about 5wt% to about 40wt%, about 10wt% to about 25wt%, about 10wt% to about 20wt%, about 12wt% to about 15wt% of the abrasive article 10, less than, equal to, or It is greater than about 5 wt%, 10, 15, 20, 25, 30, 35, or 40 wt%, but it is not so limited. The fiber component 18 may include a plurality of individual fibers 20 that are randomly oriented and entangled with respect to each other. The individual fibers 20 are joined to each other at the point of mutual contact. The individual fibers 20 may be short fibers or continuous fibers. As generally understood, "staple fiber" refers to fibers of discrete lengths, and "continuous fiber" refers to fibers that can be any suitable fiber; or filaments, such as synthetic filaments; Or inorganic fibers, such as steel filaments, glass fibers, and basalt fibers. The steel may be stainless steel, carbon steel, or include metals such as copper or alloys such as brass. The individual fibers 20 may be in the range of from about 70wt% to about 100wt%, from about 80wt% to about 90wt% of the fiber component 18, less than, equal to, or greater than about 70wt%, 75, 80, 85, 90 of the fiber component 18 , 95, or 100wt%. In further embodiments, the nonwoven web 12 may be free of fiber components 18 or individual fibers 20, and may alternatively include a sponge or foam material that includes random or ordered cavities.

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

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

In the example of an abrasive article that includes a blend of individual staple fibers, the first and second pluralities of individual staple fibers may occupy different portions of the fiber component 18. For example, the first plurality of individual fibers 20 may range from about 20wt% to about 80wt%, about 30wt% to about 40wt%, less than, equal to, or greater than about 20wt%, 25, 30, 35, 35 40, 45, 50, 55, 60, 65, 70, 75, or 80wt%. The range of the second plurality of individual fibers 20 can be from about 20 wt% to about 80 wt%, about 60 wt% to about 70 wt%, less than, equal to, or greater than about 20 wt%, 25, 30, 35, 40 of the fiber component 18 , 45, 50, 55, 60, 65, 70, 75, or 80wt%. Although two pluralities of individual staple fibers are discussed in this article, the scope of the present disclosure includes additional pluralities of individual staple fibers, such as the linear density value, crimp index, and/or of the first and second pluralities of individual fibers 20 A third plurality of individual staple fibers different in at least one of the lengths.

The individual fibers 20 of the nonwoven web 12 may include many suitable materials. Factors influencing the choice of material include: whether the material is suitably compatible with the adhesion adhesive and abrasive particles 22, and can also be processed in combination with other components of the abrasive article 10; The ability to use the processing conditions (for example, temperature). The material of the fiber 20 can also be selected to affect the properties of the abrasive article 10, such as, for example, flexibility, elasticity, durability or longevity, abrasion resistance, and finishing properties. can Examples of suitable fibers 20 include natural fibers, synthetic fibers, and mixtures of natural and/or synthetic fibers. Examples of synthetic fibers include polyester (e.g., polyethylene terephthalate), nylon (e.g., nylon-6,6, polycaprolactam), polypropylene, acrylonitrile (e.g., acrylic) , Rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, polyester (for example, polyterephthalate), and vinyl chloride-acrylonitrile copolymer. Examples of suitable natural fibers include cotton, wool, jute, and hemp. Some individual fibers 20 may include inorganic materials, steel, glass, or basalt. The steel may be stainless steel, carbon steel, or include metals such as copper or alloys such as brass. The individual fibers 20 may be virgin materials or may be recycled or discarded materials, for example, recycled from clothing tailoring, carpet manufacturing, fiber manufacturing, or textile processing. The individual fibers 20 may be homogeneous or composite, such as binary fibers (e.g., co-spun sheath-core fibers). The individual fibers 20 can be tentered and crimped short fibers.

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

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

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

The shaped abrasive particles 22 can be applied to the fibers as individual abrasive particles (e.g., without a binder to hold the particles 22 together and applied to the fiber 20) or as a binder (e.g., with a binder to hold the particles 22 together) And applied to the fiber 20). Some viscosities may include glass bonded or resin bonded particles 22. The viscose polymer may include crushed abrasive particles, particles 22.

The shaped abrasive particles 22 include any one or more particles having at least a portion of the abrasive particles of a predetermined shape. The predetermined shape can be copied, for example, from a mold cavity used to form the shaped precursor abrasive particles. In the embodiment where the shaped abrasive particles 22 are formed in the mold cavity, the predetermined geometric shape can be substantially replicated to form the cavity of the shaped abrasive particles 22. In the example of forming the shaped abrasive particles 22 by extrusion, the shaped abrasive particles 22 can also replicate the shape of the mold. If the shaped abrasive particles 22 or the abrasive article 10 are formed through a build-up process, the shaped abrasive particles 22 can also be copied in a program (For example, a computer-aided-design (CAD) program) found in the shape. The shaped abrasive particles 22 do not refer to random-sized crushed abrasive particles formed, for example, by a mechanical crushing operation.

As an example of the shaped abrasive particles 22 having a flat triangular column shape, FIGS. 3A to 3B show the triangular columnar abrasive particles 22 defined by the following: a triangular column base 30; a triangular column top 32; and a plurality of side walls 34A, 34B , 34C, the plurality of side walls connect the base 30 and the top 32. The base 30 has tips 36A, 36B, 36C, the tips having an average radius of curvature less than 50 microns. 3C to 3D show a surface of the shaped abrasive particles 22 to better show the radius of curvature of the tip 36A. Generally speaking, the smaller the radius of curvature, the sharper the edge of the side wall. In some cases, the base and top of the shaped abrasive particles are substantially parallel, resulting in a prismatic or truncated pyramid (as shown in FIGS. 3A to 3B) shape, but this is not a requirement. As shown, the side walls 34A, 34B, and 34C are of equal size and form a dihedral angle with the base 30 of about 82 degrees. However, it will be understood that other dihedral angles (including 90 degrees) may also be used. For example, the dihedral angle between the base and each of the side walls may independently be in the range of 45 to 90 degrees, 70 to 90 degrees, or 75 to 85 degrees.

4A to 4E show examples of shaped abrasive particles 22 having a tetrahedral shape. As shown in FIGS. 4A to 4E, the tetrahedral shaped abrasive particles 22 are shaped into regular tetrahedrons. As shown in FIG. 4A, the tetrahedral shaped abrasive particle 22A has six edges (50A, 52A, 54A, 56A, 58A, and 60A) that terminate at four tips (62A, 64A, 66A, and 68A). The four connected faces (42A, 44A, 46A, and 48A). Each of these faces touches the other three faces at the edge. although Figure 4A depicts a regular tetrahedron (for example, having six equal edges and four faces), but it will be recognized that other shapes are also permissible. For example, the tetrahedral shaped abrasive particles 22A may be shaped as irregular (for example, edges with different lengths) tetrahedrons.

4B, the tetrahedral shaped abrasive particles 22B have six edges (50B, 52B, 54B, 56B, 58B, and 60B) that terminate at four tips (62B, 64B, 66B, and 68B). The four sides of the connection (42B, 44B, 46B, and 48B). Each of these faces is concave and touches the other three faces at their respective common edges. Although FIG. 4B depicts particles with tetrahedral symmetry (for example, four triple-symmetrical rotation axes and six symmetrical reflection planes), it will be recognized that other shapes are also acceptable. For example, the tetrahedral shaped abrasive particles 22B may have one, two, or three concave surfaces, while the rest are flat.

4C, the tetrahedral shaped abrasive particles 22C have six edges (50C, 52C, 54C, 56C, 58C, and 60C) that terminate at four tips (62C, 64C, 66C, and 68C). The four sides of the connection (42C, 44C, 46C, and 48C). Each of these faces is convex and touches the other three faces at their respective common edges. Although the particles with tetrahedral symmetry are depicted in FIG. 4C, it will be recognized that other shapes are also permissible. For example, the tetrahedral shaped abrasive particles 22C may have one, two, or three convex surfaces, while the rest are flat or concave.

Referring now to FIG. 4D, the tetrahedral shaped abrasive particles 22D have six edges (50D, 52D, 54D, 56D, 58D, and 60D) that terminate at four tips (62D, 64D, 66D, and 68D). The four sides of the connection (42D, 44D, 46D, and 48D). Although Figure 4D depicts a particle with tetrahedral symmetry, it will be recognized that its His shape is also allowable. For example, the tetrahedral shaped abrasive particles 22D may have one, two, or three convex surfaces, while the rest are flat.

Deviations from the depiction of FIGS. 4A to 4D may exist. Figure 4E depicts an example of this tetrahedral shaped abrasive particle 22E, which shows that the tetrahedral shaped abrasive particle 22E has six edges ending at four tips (62E, 64E, 66E, and 68E) (50E, 52E, 54E, 56E, 58E, and 60E) connected four faces (40E, 44E, 46E, and 48E). Each of these faces touches the other three faces at their respective common edges. Each of the faces, edges, and tips has an irregular shape.

Any of the shaped abrasive particles 22 can include any number of shape features. The shape feature can help improve the cutting performance of any of the shaped abrasive particles 22. Examples of suitable shape features include openings, concave surfaces, convex surfaces, grooves, ridges, broken surfaces, low roundness factors, or perimeters containing one or more corner points with sharp tips. Individual shaped abrasive particles can include any one or more of these features.

The shaped abrasive particles 22 can be oriented on the individual fibers 20 in any suitable manner. The shaped abrasive particles 22 can be oriented by applying a magnetic field. Alternatively, the shaped abrasive particles 22 can be oriented by placing them in a mold or screen, wherein the individual cavities are arranged in a predetermined pattern. The amount of oriented and shaped abrasive particles 22 can be controlled. For example, at least a portion of the total number of shaped abrasive particles 22 may be oriented such that the tip is oriented substantially parallel to the direction of the line traveling through the first major surface 14 and the second major surface 16. The individual tips can be completely aligned with the lines traveling through the first major surface 14 and the second major surface 16, but the tips can also deviate from about 1 degree to about 20 degrees, about 1 degree to about 15 degrees. Full alignment, deviation from full alignment is less than, equal to, or greater than about 1 degree, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or about 20 degrees.

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

The shaped abrasive particles 22 may be further oriented on the individual fibers 20 such that at least a portion of the total number of shaped abrasive particles 22 includes a surface that is oriented to travel substantially perpendicular to the first major surface 14 and the first major surface 14 One direction of one line of the two main surfaces 16. In addition, in some embodiments, the shaped abrasive particles 22 are disposed in the gap between two more individual fibers 20 and are held in place by the resin in contact with one or more fibers 20. The individual faces can be perfectly perpendicular to the line traveling through the first major surface 14 and the second major surface 16, but the faces can also deviate from full alignment within about 1 degree to about 20 degrees, and about 1 degree to about 15 degrees. Deviation from full alignment is less than, equal to, or greater than about 1 degree, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, Or about 20 degrees.

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

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

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

The abrasive article 10 may also include conventional (e.g., crushed) abrasive particles. Examples of useful conventional abrasive particles include any abrasive particles known in the field of grinding technology. Examples of useful abrasive particles include fused alumina-based materials (such as alumina, ceramic alumina (which may include one or more metal oxide modifiers and/or seeding agents or nucleating agents) and heat-treated Alumina), silicon carbide, eutectic zirconium corundum, diamond, cerium oxide, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, emery, sol-gel derived abrasive particles, and mixtures thereof.

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

The shaped abrasive particles 22 or crushed abrasive particles may include any suitable material or mixture of materials. For example, the shaped abrasive particles 22 may include materials selected from the group consisting of alpha alumina, fused alumina, heat-treated alumina, ceramic alumina, sintered alumina, silicon carbide, titanium diboride, boron carbide, tungsten carbide , Titanium carbide, diamond, cubic boron nitride, garnet, zirconium corundum, sol-gel derived abrasive particles, cerium oxide, zirconium oxide, titanium oxide, and combinations thereof. In some embodiments, the shaped abrasive particles 22 and the crushed abrasive particles may include the same material. In further embodiments, the shaped abrasive particles 22 and the crushed abrasive particles may include different materials.

Filler particles may also be included in the abrasive article 10. Examples of useful fillers include metal carbonates (such as calcium carbonate, calcium magnesium carbonate, sodium carbonate, magnesium carbonate), silica (such as quartz, glass beads, glass bubbles, and glass fibers), silicates (such as talc, Clay, montmorillonite, feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminum silicate, sodium silicate), metal sulfates (such as calcium sulfate, barium sulfate, sodium sulfate, sodium aluminum sulfate, Aluminum sulfate), gypsum, vermiculite, sugar, wood flour, hydrated aluminum compounds, carbon black, metal oxides (such as calcium oxide, aluminum oxide, tin oxide, titanium dioxide), metal sulfites (such as calcium sulfite), thermoplastic Particles (such as polycarbonate, polyetherimide, polyester, polyethylene, poly(vinyl chloride), polysulfide, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, condensation Aldehyde polymers, polyurethane, nylon particles), and thermosetting particles (such as phenol foam, phenol beads, polyurethane foam particles, and the like). The filler can also be a salt, such as a halide salt. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride, and magnesium chloride. Examples of metal fillers include tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Other miscellaneous fillers Including sulfur, organic sulfur compounds, graphite, lithium stearate, and metal sulfides. In some embodiments, the individual shaped abrasive particles 22 or individual crushed abrasive particles may be at least partially coated with an amorphous, ceramic, or organic coating. Examples of suitable components of the coatings include silane, glass, iron oxide, aluminum oxide, or combinations thereof. Coatings such as these can help processability and the resin that binds the particles to the adhesive.

The abrasive article 10 may further include a heat-activated water-forming inorganic component. The thermally activated water-forming inorganic component can be dispersed throughout the nonwoven web 12. The thermally activated water-forming inorganic component can be in the range of from about 1wt% to about 20wt%, from about 3wt% to about 10wt% of the abrasive article 10, less than, equal to, or greater than about 1wt%, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, or about 20wt%. The endothermic heat activated water-forming inorganic component is characterized by its ability to dehydrate (e.g., release water) when exposed to elevated temperatures. The release of water can be used to cool the abrasive article 10 during use.

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

The heat-activated water-forming inorganic component may include any suitable material or mixture of materials. For example, the heat-activated water-forming inorganic component may include a metal hydroxide. The metal of the metal hydroxide can include aluminum, beryllium, cobalt, copper, glutinous, gold, iron, mercury, nickel, tin, Gallium, lead, thallium, zinc, zirconium, calcium, potassium, magnesium, lithium, sodium, alloys thereof, or mixtures thereof. Specific examples of metal hydroxides include lithium hydroxide, sodium hydroxide, potassium hydroxide, aluminum hydroxide, beryllium hydroxide, cobalt (II) hydroxide, copper (II) hydroxide, bromine hydroxide, gold hydroxide ( III), iron hydroxide (II), mercury hydroxide (II), nickel hydroxide (II), tin hydroxide (II), zinc hydroxide, zirconium (IV) hydroxide, or mixtures thereof. Specific examples of aluminum hydroxide are hydrated aluminum compounds.

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

It has surprisingly been found that the inclusion of thermally activated water-forming inorganic components, such as hydrated aluminum compounds with shaped abrasive particles 22, improves the grinding performance in abrasive articles. For example, abrasive articles that include hydrated aluminum compounds have been found to increase the grinding performance in abrasive articles used to grind carbon steel. In addition, it was surprisingly found that, compared to the corresponding abrasive article that differs only in that there is no aluminum hydrate, the abrasive article comprising hydrated aluminum compound has a higher percentage of shaped abrasive particles 22 that has a tip that Oriented in an upright position (e.g., substantially parallel to a line extending through the first major surface 12 and the second major surface 14). In addition, it was surprisingly found that, compared with the corresponding abrasive articles that differ only in the absence of aluminum hydrates, the abrasive articles including hydrated aluminum compounds have shaped abrasive particles 22 can penetrate the abrasive article 10 to the deeper percentage of the thickness of the abrasive article 10. In addition, it was surprisingly found that the abrasive article including the hydrated aluminum compound has shaped abrasive particles uniformly distributed through the abrasive article 10. It was further surprisingly found that including the aluminum hydrate compound alone or together with the crushed abrasive particles did not produce an abrasive article that performed as good as the abrasive article including the shaped abrasive particles 22 and the aluminum hydrate compound.

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

The abrasive article 10 can be made by forming a nonwoven web and applying an adhesive to the fiber component 18. A make coat may be applied to the nonwoven web 12. The nonwoven web 12 may be rolled up to substantially cover at least some of the fibers 20 protruding from the web 12. The abrasive particles 22 may be applied to the build coating to form the non-woven abrasive web 12. The construction coating is cured, and an optional size coat can be applied over the construction coating, which is then cured to form the abrasive article 10.

In some embodiments, a scrim or reinforcement layer may be attached to the non-woven abrasive mesh 12. The gauze may include any suitable material, such as polymeric film, metal foil, woven fabric, knitted fabric, paper, stiffened fiber, non-woven fabric, foam, mesh, laminate, or a combination thereof. The gauze may be attached to the non-woven mesh 12 by stitching, needle puncturing, or through an adhesive.

The nonwoven web 12 can be made, for example, by conventional air-laid, carding, stitch bonding, spunbond, wet-laid, and/or melt-blown processes. Airlaid nonwoven webs can be prepared using, for example, a web forming machine commercially available from Rando Machine Company of Macedon, N.Y. under the brand name "RANDO WEBBER". The net can also be perforated. In some examples, perforating the mesh may include needle piercing the mesh.

The non-woven abrasive web is prepared by adhering abrasive particles 22 to the non-woven web 12 with a curable second adhesive. The adhesive used to adhere the abrasive particles 22 to the nonwoven web 12 can be selected according to the requirements of the final product. Examples of the binder include polyurethane resins, phenol resins, acrylate resins, and blends of phenol resins, urea formaldehyde, latex, epoxy novolacs, epoxy resins, and acrylate resins. The coating weight of the abrasive particles 22 may depend on, for example, the specific adhesive used, the procedure for applying the abrasive particles 22 (for example, spraying), and the size of the abrasive particles 22. For example, the coating weight of the abrasive particles 22 on the nonwoven web 12 may range from 100 grams per square meter (g/m ² ) to about 5000 g/m ² , from about 1500 g/m ² to about 5000 g/m ² , or about 2000 g /m ² to about 4000g/m ² , less than, equal to, or greater than about 100g/m ² , 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600, 3700, 3800, 3900, 4000, 4100, 4200, 4300, 4400, 4500, 4600, 4700, 4800, 4900, or 5000g/m ² . The abrasive particles 12 can be coated on either or both of the first major surface and the second major surface of the nonwoven web 12. The abrasive particles 22 may be coated to achieve a substantially uniform distribution of one of the shaped abrasive particles 22 throughout the web 12.

In addition, components such as heat-activated water-forming inorganic components may be in contact with the nonwoven web 12. In some embodiments, certain components of the abrasive article 10 may be included in the slurry. For example, the slurry may include shaped abrasive particles 22, heat-activated water-forming inorganic components, materials for construction coatings and sizing coatings, crushed abrasive particles, or any other components or sub-combinations of components. The slurry can be stored and applied directly to the nonwoven web 12.

The abrasive article 10 can be used to remove material from the surface of the workpiece. This can be achieved by contacting the surface of the abrasive article 10 against the workpiece. The workpiece may be contacted, for example, with a force ranging from about 1 Newton to about 40 Newton. Then, the abrasive article 10 can move (e.g., rotate) relative to the workpiece while maintaining the pressure between the abrasive article 10 and the surface of the workpiece. Although the abrasive article 10 can have many suitable shapes, an example of a suitable shape is a disc. The abrasive article 10 can be adapted to remove many different types of materials. Examples of such materials include carbon steel, stainless steel, aluminum, or polymeric materials, such as polymeric surface coatings on workpieces.

Surprisingly, it was found that the workpiece is compared with a corresponding abrasive article remover that is operated at the same speed and differs only in that it has less heat-activated water-forming inorganic components or no heat-activated water-forming inorganic components. The larger amount is removed. It has been further surprisingly discovered that abrasive articles including thermally activated water-forming inorganic components are particularly effective in grinding carbon steel.

Instance

The following non-limiting examples further illustrate the purpose and benefits of this disclosure. However, the specific materials and quantities listed in these examples, as well as other conditions and details, should not be construed as excessively limiting the disclosure.

Use the following unit abbreviations to describe examples:

℃: the number of degrees Celsius

cm: centimeter

g/m ² : grams per square meter

Inch: 1 inch = 2.54 cm

mm: millimeter

Unless otherwise stated, all reagents are obtained from, or can be purchased from chemical suppliers, such as Sigma-Aldrich Company, St. Louis, Missouri, or can be synthesized by known methods. Unless otherwise reported, all ratios and percentages are by weight.

In the following examples, the materials are referred to as follows:

Grinding performance

Example 1

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} Then, the abrasive-coated web was cured in an oven. Table 1:

Example 2

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven.

Example 3

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} Then, the abrasive-coated web was cured in an oven.

Example 4

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 5

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of PAF was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 6

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of WC was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 7

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} The FIL in the CC form was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 8

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of KBF _{4 was} added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 9

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 1 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of K ₂ B ₁₀ O _{16 was} added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 10

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 2 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition mentioned in Table 2 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} Then, the abrasive-coated web was cured in an oven.

Example 11

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 2 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition mentioned in Table 2 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven.

Example 12

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 2 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of alumina was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 13

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 2 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of diaspore was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

Example 14

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 1 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles having the composition mentioned in Table 2 was applied to the pre-bonded air- ^{laid web at a dry additional weight of 1252.9 g/m 2.} FIL in the form of MDH1 was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven. Then, the abrasive-coated web was cured in an oven.

testing method

Off Hand

Use Roloc ^{TM to} attach and fit a 3" diameter disc. Grind the carbon steel test plate and the aluminum test plate with the coated abrasive belt corresponding to any of Examples 1 to 12 on the belt polishing machine to Linear particles are applied on the carbon steel. The average Ra on the carbon steel is 75μin, and the average Ra on the aluminum test board is 150μin. Then, the board and the disc are weighed before the test.

Hand-held grinding short test

During one minute, working in the particle direction of the individual boards, a non-woven disc according to any one of Examples 1 to 12 was used to remove scratches from one half of the board. One point in the second During the clock, work in the direction of the particles to remove scratches from the other half of the board. Then, clean and weigh the disc and the workpiece. The Ra of the board was also measured and recorded in 5 caution zones.

Hand-held grinding length test

During one minute, working in the particle direction of the individual boards, a non-woven disc according to any one of Examples 1 to 12 was used to remove scratches from one half of the board. During the second one-minute period, work in the direction of the particles to remove scratches from the other half of the board.

The plates were weighed around the 2 minute period to determine the quality loss of the plates.

Perform the above method using a new plate for another 2 minutes.

Continue this procedure for 4 plates and hand-grinding for each disc for a total of 8 minutes. Measure the surface luminosity of the first and fourth plates in 5 discreet areas of each plate. The highest and lowest surface luminosity values are discarded, and the middle 3 Ra values are averaged. Average the average surface luminosity of plate 1 and plate 4 to give the final surface luminosity value recorded as follows.

XY automatic test

Use Roloc ^{TM to} attach and fit a 3" diameter disc. The XY test disc has 8 cycles. Each cycle is 1 minute long, during which the disc grinds the flat test plate. During the test, the robotic arm moves in the X and Y directions , Grind the surface of the plate. After the first cycle and after cycle #8, check the Ra left by the disc in 5 cautious areas. Weigh the plate and the disc before cycle 1 and after cycle 8 to determine Loss of quality of substrate and disc.

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

The force used when grinding aluminum is 5lbs and 9000RPM or 5lbs and 11,0000RPM.

Abrasive article structure

Example 15

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 5 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition mentioned in Table 5 was applied to the pre-bonded airlaid web at a dry additional weight of ^{1252.9 g/m 2.} Then, the abrasive-coated web was cured in an oven.

Example 16

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 5 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition mentioned in Table 5 was applied to the pre-bonded airlaid web at a dry additional weight of ^{1252.9 g/m 2.} FIL in the form of ATH1 was added to the slurry spray at 6.2 wt%. Then, the abrasive-coated web was cured in an oven.

Example 17

An apparatus such as commercially available under the brand name "RANDO WEBBER" from Rando Machine Company of Macedon, New York) is used to form a fluffy random airlaid web (with F1 fibers and a weight of ~314 g/m ² ). The web was further needled into a flexible backing (SCR) in a knitting machine, rolled, and a pre-bonding coating having the composition mentioned in Table 5 was applied to the airlaid fabric, To reach a dry additional weight of 355g/m ^2. Then, the pre-joint is cured in an oven. A slurry coating containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition mentioned in Table 5 was applied to the pre-bonded airlaid web at a dry additional weight of ^{1252.9 g/m 2.} FIL in the form of ATH1 was added to the slurry spray at 17.6 wt%. Then, the abrasive-coated web was cured in an oven.

testing method

PSG Orientation

For Examples 15, 16, and 17, orientation maps of PSG particles were generated. The orientation graph uses the directional cosine of the short/minimum axis (PSG width) and the long/maximum axis (PSG length). Plot the Y component of the smallest axis to the Z component of the largest axis of each PSG. Each point in the picture is one Different PSG objects (ie, single PSG, PSG clusters, PSG+ crushed clusters), and display N=# for each chart, where N is the number of PSG objects measured in the scan data set. The coordinates (0,0) on the graph refer to the PSG object with perfect upright orientation (preferably orientation). Coordinates (90, 90) or (-90, -90) refer to PSG objects with straight orientation (not preferred orientation). The value between 0 and 90 on the maximum Z axis indicates the angle of the cosine relative to the direction of the vector normal to the sample gauze/plane. From these plots, it is possible to determine the percentage of particles in an upright position (PSG with an angle of <15° to the normal sample plane) and the percentage of particles in a flat orientation.

PSG penetration

X-ray microtomography analysis was used to determine the penetration depth of PSG in the nonwoven web. To execute the procedure, a strip of material was cut from each abrasive article of Examples 15, 16, and 17. A Skyscan 2211 (Bruker microCT, Kontich, Belgium) X-ray microtomography scanner was used to scan each instance with a resolution of 6.00um. Use the X-ray source to set 70kV and 110uA together with the application of a 0.5mm aluminum filter to modify the energy distribution of the incident beam to collect data. As the sample is rotated through a 360-degree angular range using a 0.10 degree angular step size, a flat panel detector is used to record the projected image at discrete sample rotation angles. Five individual detector frames are averaged for each collected projected image. The computer program NRecon (v 1.6.10, Bruker microCT, Kontich, Belgium) was used for reconstruction, which used corrections for X-ray source centering, detector ring artifacts, and beam hardening.

The resulting reconstructed image is subjected to post-processing to isolate the positions of the shaped particles within the scanned sample. One gray scale threshold allows separation of abrasive particles from non-woven structures Among the higher and lower density materials. Use the computer program CT Analyzer (v 1.16.4, Bruker microCT, Kontich, Belgium) for the initial processing of the reconstructed data set.

Subsequent size filtering of the threshold-defined image removes small unshaped abrasive particles from the image. Analyze the threshold and size-filtered images to determine the size, shape, and position (centroid coordinates of X, Y, and Z) of the shaped abrasive particles in the dataset volume. Then, the cut-off and size-filtered images are stored as separate data sets for subsequent inspection of the orientation of the shaped particles. The computer software Avizo (v 9.5.0, ThermoFisher Scientific, Hillsboro, Oregon) was used to further process the reconstructed data and for the analysis of the shaped particles.

Identify the physical location of each shaped abrasive particle in the data set and evaluate the short axis and long axis of each shaped particle. The direction cosine of the normal of the minor axis and the major axis is calculated and tabulated.

The threshold image is subjected to re-slicing along the XZ plane to obtain the depth profile image of the data set using a CT analyzer. Use Avizo to determine the area of abrasive particles for each depth profile image.

result

Table 8 shows the results of the targeted analysis.

Figures 5-7 show the total depth of PSG particles distributed through the nonwoven web. In addition, PSG is distributed in a plurality of regions. That is, one or more areas have a higher concentration of PSG along the depth of the nonwoven web. The representative regions have substantially the same PSG concentration, or each region has a different concentration. Table 9 shows the concentration of PSG in Examples 15 to 17 across the total thickness of the abrasive article. Specifically, Table 9 shows the particle wt% in the following areas: the area accounting for the top third of the total thickness; accounting for the total thickness The area of the middle third of the thickness; and the area of the bottom third of the total thickness. Table 10 shows the particle wt% in the following areas: an area accounting for the top half of the total thickness; and an area accounting for the bottom half of the total thickness.

The used terms and notations are used as descriptive terms and not as restrictive terms, and it is not intended to exclude any equivalent of the features or parts shown and described in the use of these terms and notations, but should It is recognized that various modifications are possible within the scope of the embodiments of the present disclosure. Therefore, it should be understood that although the present disclosure has been specifically disclosed through specific embodiments and optional features, those with ordinary knowledge in the technical field can make modifications and changes to the concepts disclosed herein, and these modifications And the changes are deemed to be still within the scope of the embodiments of this disclosure.

Additional examples.

The following illustrative examples are provided, and their numbers are not interpreted as specifying the degree of importance:

Embodiment 1 provides an abrasive article, which comprises:

A non-woven web, which contains

A fiber or filament component,

A first major surface, and

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

A plurality of shaped abrasive particles are dispersed through at least a part of the nonwoven web; and

A thermally activated water forming inorganic component is dispersed through the nonwoven web.

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

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

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

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

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

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

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

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

Embodiment 10 provides the abrasive article of any one of embodiments 5 to 9, wherein a crimp index value of the short fibers is in a range from about 25% to about 40%.

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

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

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

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

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

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

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

Embodiment 18 provides the abrasive article of any one of embodiments 1 to 17, wherein at least one of the shaped abrasive particles of the plurality of shaped abrasive particles is a tetrahedron, and includes a tetrahedron that terminates at four tips Each of the four faces connected by the six edges at the position touches three of the four faces.

Example 19 provides the abrasive article of Example 18, wherein at least one of the four faces is substantially flat.

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

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

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

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

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

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

Embodiment 26 provides the abrasive article of any one of embodiments 1 to 25, wherein at least one of the shaped abrasive particles of the plurality of shaped abrasive particles comprises a thickness of the shaped abrasive particles Separate a first side and a second side, the first side includes a first surface, the first mask has a triangular periphery, and the second side includes a second surface, the second mask has a triangular periphery , Wherein the thickness of the shaped abrasive particle is equal to or less than the length of the relevant dimension of the shortest side of the particle.

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

Embodiment 28 provides the abrasive article of embodiment 27, wherein the at least one side wall is an inclined side wall.

Embodiment 29 provides the abrasive article of any one of embodiments 27 or 28, wherein a draft angle α of the inclined sidewall is in a range from about 95 degrees and about 130 degrees.

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

Embodiment 31 provides the abrasive article of any one of embodiments 26 to 29, wherein the first surface and the second surface are not substantially parallel to each other.

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

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

Embodiment 34 provides the abrasive article of any one of embodiments 1 to 33, wherein at least one of the shaped abrasive particles includes at least one shape feature, and the at least one shape feature includes: an opening, a concave surface, A convex surface, a groove, a ridge, a broken surface, a low roundness factor, or a periphery including one or more corner points with a sharp tip.

Embodiment 35 provides the abrasive article of any one of embodiments 1 to 34, wherein a portion of the plurality of shaped abrasive particles independently includes a tip that is oriented substantially parallel to travel through the first main body A direction of a line of the surface and the second main surface.

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

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

Embodiment 38 provides the abrasive article of any one of embodiments 35 to 37, wherein the tip is at a distance from about 1 degree to about 20 degrees relative to the line traveling through the first major surface and the second major surface In a range.

Embodiment 39 provides the abrasive article of any one of embodiments 35 to 38, wherein the tip is at a distance from about 1 degree to about 15 degrees relative to the line traveling through the first major surface and the second major surface In a range.

Embodiment 40 provides the abrasive article of any one of embodiments 1 to 39, wherein a portion of the plurality of shaped abrasive particles independently includes a face that is oriented substantially perpendicular to travel through the first major surface And a direction of a line of the second main surface.

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

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

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

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

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

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

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

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

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

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

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

Embodiment 52 provides the abrasive article of any one of embodiments 1 to 51, wherein the shaped abrasive particles comprise a material selected from the group consisting of alpha alumina, fused alumina, heat-treated alumina, ceramic alumina, Sintered alumina, silicon carbide, titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, zirconium corundum, sol-gel derived abrasive particles, cerium oxide, zirconium oxide, titanium oxide , And combinations thereof.

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

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

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

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

Example 57 provides the abrasive article of any one of Examples 1 to 56, which further comprises a binder dispersed throughout the nonwoven web.

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

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

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

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

Embodiment 62 provides the abrasive article of any one of embodiments 1 to 61, wherein the heat-activated water-forming inorganic component is an endothermic heat-activated water-forming inorganic component having an activation temperature of about 300° C. or lower.

Embodiment 63 provides the abrasive article of any one of embodiments 1 to 62, wherein the heat-activated water-forming inorganic component is an endothermic heat-activated water-forming having an activation temperature in the range from about 200°C to about 300°C Inorganic components.

Embodiment 64 provides the abrasive article of any one of embodiments 1 to 63, wherein the heat-activated water-forming inorganic component is an endothermic heat-activated water-forming having an activation temperature in the range from about 200°C to about 250°C Inorganic components.

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

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

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

Embodiment 68 provides the abrasive article of any one of embodiments 65 to 67, wherein the metal hydroxide comprises lithium hydroxide, sodium hydroxide, potassium hydroxide, aluminum hydroxide, beryllium hydroxide, and cobalt(II) hydroxide , Copper (II) Hydroxide, Hydroxide, Gold Hydroxide (III), Iron Hydroxide (II), Mercury Hydroxide (II), Nickel Hydroxide (II), Tin Hydroxide (II), Zinc Hydroxide , Zirconium (IV) hydroxide, or a mixture thereof.

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

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

Example 71 provides the abrasive article of any one of Examples 1 to 70, which further comprises a flexible backing in contact with the first major surface or the second major surface.

Embodiment 72 provides the abrasive article of embodiment 71, wherein the flexible backing comprises a polymer film, a metal foil, a woven fabric, a knitted fabric, paper, a stiffened fiber, a short fiber, a continuous fiber, and a non-woven fabric. Fabric, a foam, a screen, a laminate, and combinations thereof.

Embodiment 73 provides an abrasive article comprising:

A non-woven web, which contains:

A fiber or filament component;

A first major surface;

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

A plurality of shaped abrasive particles are dispersed through the nonwoven web;

The aluminum trihydrate component is dispersed through the nonwoven web.

Embodiment 74 provides an abrasive article comprising:

A non-woven web, which contains:

A fiber or filament component;

A first major surface;

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

A plurality of shaped abrasive particles are dispersed through the nonwoven web;

The hydrated aluminum compound, which is dispersed through the nonwoven web,

Wherein, about 5% to about 70% of the plurality of shaped abrasive particles comprise a tip, the tip is oriented in a direction substantially perpendicular to a line traveling through the first major surface and the second major surface.

Embodiment 75 provides an abrasive article comprising:

A non-woven web, which contains:

A fiber or filament component;

A first major surface;

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

A plurality of shaped abrasive particles are dispersed through the non-woven web, wherein the shaped abrasive particles are distributed through the thickness of the non-woven web according to a plurality of distributions;

A hydrated aluminum compound dispersed through the nonwoven web, wherein the plurality of shaped abrasive particles comprise one of oriented in a direction substantially perpendicular to a line traveling through the first major surface and the second major surface A part of the tip is in a range from about 5% to about 70% of the plurality of shaped abrasive particles

Embodiment 76 provides a slurry, which comprises:

Plural shaped abrasive particles;

Thermally activated water forming inorganic components; and

Adhesive

Lubricant; and

Solvent.

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

Embodiment 78 provides the slurry of any one of embodiments 76 or 77, wherein the abrasive particles range from about 2 wt% to about 70 wt% of the slurry.

Embodiment 79 provides the slurry of any one of embodiments 76 to 78, wherein the abrasive particles range from about 5 wt% to about 70 wt% of the slurry.

Embodiment 80 is the slurry of any one of embodiments 76 to 79, wherein the binder is in a range from about 10% by weight to about 70% by weight of the slurry.

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

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

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

Embodiment 84 provides the slurry of any one of embodiments 76 to 83, wherein the heat-activated water-forming inorganic component contains an endothermic heat-activated water-forming inorganic component at a reaction temperature of about 300° C. or lower.

Embodiment 85 provides the slurry of any one of embodiments 76 to 84, wherein the thermally activated water-forming inorganic component has an endothermic heat activation at a reaction temperature in a range from about 200°C to about 300°C Water forms inorganic components.

Embodiment 86 provides the slurry of any one of embodiments 76 to 85, wherein the heat-activated water-forming inorganic component comprises an endothermic heat activation at a reaction temperature in a range from about 200°C to about 250°C Water forms inorganic components.

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

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

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

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

Embodiment 91 provides a method of manufacturing the abrasive article of any one of Embodiments 1 to 90, which comprises:

Forming a nonwoven web of one of the fibers or filaments;

Perforate the net;

Applying the abrasive particles and binder to the perforated net; and

The adhesive is cured to provide the abrasive article.

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

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

Embodiment 94 provides the method of any one of embodiments 91 to 93, wherein the abrasive particles are applied to the nonwoven web with an additional weight ^{ranging from about 100 g/m 2} to about 5000 g/m ^2.

Embodiment 95 provides the method of any one of embodiments 91 to 94, wherein the abrasive particles are applied to the nonwoven web with an additional weight ^{ranging from about 2000 g/m 2} to about 4000 g/m ^2.

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

Example 97 provides the methods of Examples 91 to 96, wherein the fibers are airlaid using a web forming machine.

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

Contacting the abrasive article as in any one of embodiments 1 to 75 or the abrasive article formed by the method as in any one of embodiments 91 to 97 against the workpiece; and

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

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

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

Example 101 provides the method of any one of Examples 98 to 100, wherein the method is operated at the same speed and differs only in that it has less heat-activated water-forming inorganic components or no heat-activated water-forming inorganic components. Compared to the remover of the corresponding abrasive article, a larger amount of the workpiece is removed.

10: Abrasive items

12: Non-woven mesh/non-woven abrasive mesh/net

14: The first major surface

16: second major surface

18: Fiber component

20: Fiber

22: Abrasive particles/particles

24: Adhesive

Claims (15)

An abrasive article comprising: A non-woven web, which contains: A fiber or filament component, A first major surface, and A second major surface, wherein a thickness of the nonwoven web is defined from the first major surface to the second major surface; A plurality of individual shaped abrasive particles are dispersed through at least a part of the nonwoven web; and A thermally activated water forming inorganic component is dispersed through the nonwoven web. The abrasive article of claim 1, wherein the fibers comprise materials selected from the group consisting of polyester, nylon, polypropylene, acrylic, rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, vinyl chloride -Acrylonitrile copolymers, and combinations thereof. The abrasive article of any one of claim 1 or 2, wherein in a plurality of regions, the individual shaped abrasive particles are distributed throughout the thickness of the nonwoven web. The abrasive article of any one of claims 1 to 3, wherein the individual shaped abrasive particles comprise a material selected from the group consisting of alpha alumina, fused alumina, heat-treated alumina, ceramic alumina, and sintered alumina , Silicon carbide, titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, zirconium corundum, sol-gel derived abrasive particles, cerium oxide, zirconium oxide, titanium oxide, and combination. The abrasive article according to any one of claims 1 to 4, wherein the heat-activated water-forming inorganic component is in a range from about 1 wt% to about 20 wt% of the abrasive article. The abrasive article according to any one of claims 1 to 5, wherein the heat-activated water-forming inorganic component is an endothermic heat-activated water-forming inorganic component having an activation temperature of about 300° C. or lower. The abrasive article according to any one of claims 1 to 6, wherein the heat-activated water-forming inorganic component comprises a metal hydroxide. The abrasive article of claim 7, wherein the metal hydroxide is an aluminum hydrate compound. An abrasive article comprising: A non-woven web, which contains: A fiber or filament component; A first major surface; A second major surface, wherein a thickness of the nonwoven web is defined between the first major surface and the second major surface; A plurality of individual shaped abrasive particles are dispersed through the nonwoven web; and The hydrated aluminum compound is dispersed through the nonwoven web. A method for making the abrasive article according to any one of claims 1 to 9, which comprises: Forming a nonwoven web of one of the fibers or filaments; Perforate the net; Applying the abrasive particles and binder to the perforated net; and The adhesive is cured to provide the abrasive article. The method of claim 10, wherein forming the nonwoven web of fibers comprises air-laid the fibers. A method for removing material from the surface of a workpiece, the method comprising: Make the abrasive article as in any one of claims 1 to 9 or by such as claim 10 or 11 The abrasive article formed by any one of the methods is in contact with the workpiece; and The abrasive article is moved relative to the workpiece while maintaining pressure between the abrasive article and the surface of the workpiece to remove material from the surface of the workpiece. The method of claim 12, wherein the abrasive article is in the shape of a disc, the disc has a central axis, and the movement of the abrasive article relative to the workpiece is achieved by rotating the abrasive article around the central axis . The method of any one of claim 12 or 13, wherein the material removed from the workpiece is carbon steel. The method of any one of claims 12 to 14, wherein it is operated at the same speed and differs only in a corresponding abrasive article having less heat-activated water-forming inorganic components or no heat-activated water-forming inorganic components Compared with the remover, a larger amount of the workpiece is removed.

Images