US20210308833A1 - Fixed abrasive buff - Google Patents

Fixed abrasive buff Download PDF

Info

Publication number
US20210308833A1
US20210308833A1 US17/212,091 US202117212091A US2021308833A1 US 20210308833 A1 US20210308833 A1 US 20210308833A1 US 202117212091 A US202117212091 A US 202117212091A US 2021308833 A1 US2021308833 A1 US 2021308833A1
Authority
US
United States
Prior art keywords
abrasive
buff
fabric layers
layers
composition
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
US17/212,091
Other languages
English (en)
Inventor
Sathanjheri RAVISHANKAR
Paul S. Goldsmith
Daniel E. SYMEON
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
Original Assignee
Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint Gobain Abrasifs SA, Saint Gobain Abrasives Inc filed Critical Saint Gobain Abrasifs SA
Priority to US17/212,091 priority Critical patent/US20210308833A1/en
Assigned to SAINT-GOBAIN ABRASIVES, INC., SAINT-GOBAIN ABRASIFS reassignment SAINT-GOBAIN ABRASIVES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SYMEON, DANIEL E., GOLDSMITH, PAUL S., RAVISHANKAR, SATHANJHERI
Publication of US20210308833A1 publication Critical patent/US20210308833A1/en
Pending legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D13/00—Wheels having flexibly-acting working parts, e.g. buffing wheels; Mountings therefor
    • B24D13/02—Wheels having flexibly-acting working parts, e.g. buffing wheels; Mountings therefor acting by their periphery
    • B24D13/12—Wheels having flexibly-acting working parts, e.g. buffing wheels; Mountings therefor acting by their periphery comprising assemblies of felted or spongy material, e.g. felt, steel wool, foamed latex

Definitions

  • buffs and buffing wheels are used to polish components formed from various metals, plastics, ceramics, among others. These conventional buffs are typically free of any fixed abrasive material and are generally used in a so-called buffing process to polish or surface finish components formed from various materials (e.g., metals, plastics, ceramics, etc.). Instead of containing a fixed abrasive material, abrasive buffing emulsions or compounds are externally applied to the working surface of the conventional buffs, and periodically reapplied, during polishing operations.
  • the present disclosure relates generally to a fixed abrasive buff that includes a central hub, a plurality of fabric layers affixed to the central hub, and an abrasive composition disposed throughout or embedded within the plurality of fabric layers.
  • the abrasive composition includes a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder.
  • a content of the abrasive particles at an outer edge of the plurality of fabric layers may be higher than the content of the abrasive particles at an inner edge of the plurality of fabric layers.
  • FIG. 1 is an image of a fixed abrasive buff according to an embodiment of the disclosure.
  • FIG. 2 is a flowchart of a method 200 of forming a fixed abrasive buff according to an embodiment of the disclosure.
  • FIG. 3A is an image of an uncoated buff mounted to a rotation device prior to coating with an abrasive composition according to an embodiment of the disclosure.
  • FIG. 3B is an image of an uncoated buff submerged into and being rotated within an abrasive composition according to an embodiment of the disclosure.
  • FIG. 3C is an image of a fixed abrasive buff coated with and removed from the abrasive composition according to an embodiment of the disclosure.
  • FIG. 3D is an image of a fixed abrasive buff coated with the abrasive composition after spinning to remove the excess abrasive composition according to an embodiment of the disclosure.
  • FIG. 4A shows an apparatus having a pressurized air delivery device according to an embodiment of the disclosure.
  • FIG. 4B shows an image of a pressurized air delivery device according to an embodiment of the disclosure.
  • FIG. 5A is an image of a used control abrasive buff with no abrasive composition.
  • FIG. 5B is an image of a used sample fixed abrasive buff according an embodiment of the disclosure.
  • FIG. 6A is an image of a brass panel buffed by the control abrasive buff with no abrasive composition.
  • FIG. 6B is an image of a brass panel buffed by a sample fixed abrasive buff according to an embodiment of the disclosure.
  • FIG. 7 shows a chart providing comparative data of surface finish (Ra) versus time of a control fixed abrasive buff and an embodiment of a sample fixed abrasive buff.
  • FIG. 8 shows a chart providing comparative data of surface finish (Rz) versus time of a control fixed abrasive buff and an embodiment of a sample fixed abrasive buff.
  • FIG. 9 shows a chart providing comparative data of cumulative material removal versus time of a control fixed abrasive buff and an embodiment of sample fixed abrasive buff.
  • FIG. 10 shows a chart providing comparative data of surface finish (Ra) versus time of a control fixed abrasive buff and an embodiment of a sample fixed abrasive buff.
  • FIG. 11 shows a chart providing comparative data of surface finish (Rz) versus time of a control fixed abrasive buff and an embodiment of a sample fixed abrasive buff.
  • FIG. 12 shows a chart providing comparative data of cumulative material removal versus time of a control fixed abrasive buff and an embodiment of sample fixed abrasive buff.
  • FIG. 13 shows a chart providing comparative data of required power versus time of a control fixed abrasive buff and an embodiment of sample fixed abrasive buff.
  • FIG. 14 shows an image of a deconstructed sample fixed abrasive buff with sample strips removed.
  • FIG. 1 shows an image of a fixed abrasive buff 100 according to an embodiment of the disclosure.
  • the fixed abrasive buff 100 generally comprises a central hub 102 , a plurality of fabric layers 104 affixed to the central hub 102 , and an abrasive composition 106 disposed throughout or embedded within the plurality of fabric layers 104 .
  • the abrasive composition 106 comprises a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder.
  • the abrasive composition 106 may generally be disposed throughout or embedded within the plurality of fabric layers 104 , such that the abrasive composition 106 (including the abrasive particles) penetrates into and between the fibers of each of the plurality of fabric layers 104 of the fixed abrasive buff 100 .
  • FIG. 2 shows a flowchart of a method 200 of forming a fixed abrasive buff 100 according to an embodiment of the disclosure.
  • Method 200 may begin at block 202 by providing an uncoated buff comprising a central hub 102 and a plurality of fabric layers 104 affixed to the central hub 102 .
  • Method 200 may continue at block 204 by at least partially submerging the uncoated buff into an abrasive composition 106 having a polymeric binder and a plurality of abrasive particles.
  • Method 200 may continue at block 206 by rotating the buff within the abrasive composition 106 .
  • Method 200 may continue at block 208 by applying pressure to the plurality of fabric layers 104 to cause the plurality of fabric layers 104 to splay or separate each of the fabric layers from one another during the coating process.
  • the splaying of the plurality of fabric layers 104 may be accomplished by applying or directing pressurized air radially towards the plurality of fabric layers 104 to cause the plurality of fabric layers 104 to splay or separate from one another.
  • the splaying of the plurality of fabric layers 104 may be accomplished by pressing the plurality of fabric layers 104 against a sidewall of a container holding the abrasive composition 106 to cause the plurality of fabric layers 104 to splay or separate from one another.
  • the steps at blocks 206 and 208 may be performed simultaneously, so as to continuously apply pressure to the plurality of fabric layers 104 to cause the plurality of fabric layers 104 to splay or separate from one another while rotating the buff within the abrasive composition 106 to coat the plurality of fabric layers 104 with the abrasive composition 106 to form a fixed abrasive buff 100 .
  • rotating the buff within the abrasive composition 106 to coat the plurality of fabric layers 104 with the abrasive composition 106 may result in a higher concentration, higher content, and/or higher add-on or total weight of the abrasive composition 106 at an outer edge of the plurality of fabric layers 104 as compared to the concentration, content, and/or weight of the abrasive composition 106 at an inner edge, adjacent to the central hub 102 , of the plurality of fabric layers 104 .
  • method 200 may result in better penetration of the abrasive composition 106 into the plurality of fabric layers 104 of the fixed abrasive buff 100 .
  • Method 200 may continue at block 210 by removing the fixed abrasive buff 100 from the abrasive composition 106 and rotating the fixed abrasive buff 100 to spin off excess abrasive composition 106 .
  • the fixed abrasive buff 100 may be removed entirely from the abrasive composition 106 and rotated at a controlled rate to facilitate removal of excess abrasive composition.
  • the rate of rotation may be controlled to facilitate other features of the fixed abrasive buff 100 as described in embodiments herein.
  • Method 200 may continue at block 212 by curing the abrasive composition 106 on the fixed abrasive buff 100 .
  • curing the abrasive composition 106 may comprise allowing sufficient time for the abrasive composition 106 to harden and/or solidify.
  • curing the abrasive composition 106 may comprise a process that accelerates drying or induces curing, such as applying heat to (e.g., baking, etc.) the fixed abrasive buff 100 .
  • one or more process steps including for example, but not limited to, the process of applying pressure to the plurality of fabric layers 104 may facilitate particular distributions of the abrasive particles in a given layer as well as differences in the distribution of abrasive particles from layer-to-layer.
  • FIGS. 3A to 3D show various steps of an embodiment in forming a fixed abrasive buff 100 .
  • FIG. 3A shows an uncoated buff comprising a central hub 102 and a plurality of fabric layers 104 affixed to the central hub 102 according to an embodiment of the disclosure. The uncoated buff is mounted to a rotation device via the central hub 102 and is suspended above a fixed container holding the abrasive composition 106 .
  • FIG. 3B shows the buff submerged into the abrasive composition 106 and being rotated to coat the plurality of fabric layers 104 with the abrasive composition 106 .
  • the plurality of fabric layers 104 are also being pressed against a sidewall of the fixed container holding the abrasive composition 106 to cause the plurality of fabric layers 104 to splay or separate from one another.
  • pressurized air may be radially applied to portions of the plurality of fabric layers 104 that are rotated out of the abrasive composition 106 to cause the plurality of fabric layers 104 to splay or separate from one another while being rotated through the abrasive composition 106 .
  • FIG. 3C shows the fixed abrasive buff 100 removed from the abrasive composition 106 .
  • 3D shows the fixed abrasive buff 100 coated with the abrasive composition 106 after spinning the fixed abrasive buff 100 to remove the excess abrasive composition 106 . Once cured, the fixed abrasive buff will be ready for use in a buffing process to polish or surface finish a workpiece.
  • FIG. 4A shows an apparatus 150 having a pressurized air delivery device 152 for applying or directing compressed air to portions of the plurality of fabric layers 104 to cause the plurality of fabric layers 104 to splay or separate from one another while being rotated by a rotation device 154 through the abrasive composition 106 .
  • An uncoated buff may be mounted to the rotation device 154 via the central hub 102 and suspended at least partially within the abrasive composition 106 .
  • the pressurized air delivery device 152 may be connected to an air compressor or other compressed air delivery device.
  • the pressurized air delivery device 152 may radially apply or direct pressurized air to portions of the plurality of fabric layers 104 that are rotated out of the abrasive composition 106 to cause the plurality of fabric layers 104 to splay or separate from one another while being rotated through the abrasive composition 106 , which may result in a higher concentration, higher content, and/or higher weight of the abrasive composition 106 at an outer edge of the plurality of fabric layers 104 as compared to the concentration, content, and/or weight of the abrasive composition 106 at an inner edge, adjacent to the central hub 102 , of the plurality of fabric layers 104 .
  • the pressurized air delivery device 152 comprises a plurality of air delivery holes.
  • the number of air delivery holes in the pressurized air delivery device 152 may be selected based on the width, diameter, number of fabric layers 104 , or other characteristics of the fixed abrasive buff 100 .
  • rotating the buff within the abrasive composition 106 to coat the plurality of fabric layers 104 with the abrasive composition 106 may result in a higher concentration, higher content, and/or higher weight of the abrasive composition 106 at an outer edge of the plurality of fabric layers 104 as compared to the concentration, content, and/or weight of the abrasive composition 106 at an inner edge, adjacent to the central hub 102 , of the plurality of fabric layers 104 .
  • This may provide beneficial surface finish characteristics since more abrasive particles are disposed at the outer periphery of the plurality of fabric layers 104 of the fixed abrasive buff 100 where the majority of surface finishing of a workpiece occurs.
  • the content of the abrasive particles at the outer edge of the plurality of fabric layers 104 may be higher than the content of the abrasive particles at the inner edge, adjacent to the central hub 102 , of the plurality of fabric layers 104 . In some embodiments, the content of the abrasive particles at the outer edge of the plurality of fabric layers 104 may be at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the content of the abrasive particles at the inner edge of the plurality of fabric layers 104 .
  • the content of the abrasive particles at the outer edge of the plurality of fabric layers 104 may be not greater than 300%, not greater than 200%, not greater than 100%, not greater than 90%, not greater than 80%, not greater than 70%, not greater than 60%, or not greater than 50% higher than the content of the abrasive particles at the inner edge of the plurality of fabric layers 104 .
  • the content of the abrasive particles at the outer edge of the plurality of fabric layers 104 may be between any of these minimum and maximum values, such as at least 10% to not greater than 300% higher than the content of the abrasive particles at the inner edge of the plurality of fabric layers 104 , or even at least 50% to not greater than 100% higher than the content of the abrasive particles at the inner edge of the plurality of fabric layers 104 .
  • the content at the outer edge is 52% higher than the content at the inner edge of the plurality of fabric layers 104 .
  • the add-on weight of the abrasive composition 104 at the outer edge of the plurality of fabric layers 104 may be higher than the add-on weight of the abrasive composition 104 at the inner edge, adjacent to the central hub 102 , of the plurality of fabric layers 104 .
  • the add-on weight of the abrasive composition 104 at the outer edge of the plurality of fabric layers may be at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the add-on weight of the abrasive composition 104 at the inner edge of the plurality of fabric layers 104 .
  • the add-on weight of the abrasive composition 104 at the outer edge of the plurality of fabric layers may be not greater than 300%, not greater than 200%, not greater than 100%, not greater than 90%, not greater than 80%, not greater than 70%, not greater than 60%, or not greater than 50% higher than the add-on weight of the abrasive composition 104 at the inner edge of the plurality of fabric layers 104 .
  • the add-on weight of the abrasive composition 104 at the outer edge of the plurality of fabric layers 104 may be between any of these minimum and maximum values, such as at least 10% to not greater than 300% higher than the add-on weight of the abrasive composition 104 at the inner edge of the plurality of fabric layers 104 , or even at least 50% to not greater than 100% higher than the add-on weight of the abrasive composition 104 at the inner edge of the plurality of fabric layers 104 .
  • the add-on weight of the abrasive composition 104 at the outer edge may be 1.295 grams, and the add-on weight of the abrasive composition 104 at the inner edge may be 0.623 grams.
  • the add-on weight of the abrasive composition 104 at the outer edge is 52% higher than the add-on weight of the abrasive composition 104 at the inner edge.
  • the total weight of the fixed abrasive buff 100 at the outer edge of the plurality of fabric layers 104 may be higher than the total weight at the inner edge, adjacent to the central hub 102 , of the plurality of fabric layers 104 . In some embodiments, the total weight of the fixed abrasive buff 100 at the outer edge of the plurality of fabric layers may be at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the total weight at the inner edge of the plurality of fabric layers 104 .
  • the total weight of the fixed abrasive buff 100 at the outer edge of the plurality of fabric layers may be not greater than 300%, not greater than 200%, not greater than 100%, not greater than 90%, not greater than 80%, not greater than 70%, not greater than 60%, or not greater than 50% higher than the total weight at the inner edge of the plurality of fabric layers 104 .
  • the total weight of the fixed abrasive buff 100 at the outer edge of the plurality of fabric layers 104 may be between any of these minimum and maximum values, such as at least 10% to not greater than 300% higher than the total weight of the fixed abrasive buff 100 at the inner edge of the plurality of fabric layers 104 , or even at least 50% to not greater than 100% higher than the total weight of the fixed abrasive buff 100 at the inner edge of the plurality of fabric layers 104 .
  • the total weight of the abrasive composition 104 at the outer edge is 32% higher than the total weight of the abrasive composition 104 at the inner edge.
  • the plurality of fabric layers 104 may generally be made from any number of various materials, including woven fabrics, nonwoven fabrics, or a combination thereof.
  • the fabric layers 104 may be formed from a plurality of fibers or yarns, such as natural fibers or yarns, synthetic fibers or yarns, or a combination thereof.
  • the natural fibers or yarns can comprise one or more types of natural fibers.
  • the natural fibers or yarns may comprise cellulose fibers or yarns, cotton fibers or yarns, flax fibers or yarns, hemp fibers or yarns, jute fibers or yarns, ramie fibers or yarns, sisal fibers or yarns, linen fibers or yarns, silk fibers or yarns, or a combination thereof.
  • natural fibers or yarns may consist essentially of cotton fibers or yarns.
  • the synthetic fibers or yarns may comprise one or more types of synthetic fibers or yarns.
  • the synthetic fibers or yarns may comprise glass fibers or yarns, polymeric fibers or yarns, or a combination thereof.
  • the polymeric fibers or yarns may comprise acrylic fibers or yarns, nylon fibers or yarns, olefin fibers or yarns, polyester fibers or yarns, rayon fibers or yarns, modal fibers or yarns, or a combination thereof.
  • the synthetic fibers consist essentially of polyester fibers.
  • the synthetic fibers consist essentially of nylon fibers.
  • the plurality of fabric layers 104 may comprise a woven fabric.
  • the woven fabric can comprise a plurality of yarns, such as warp yarns and weft yarns.
  • the abrasive composition can be disposed at least partially within or between the yarns, such as between the warp and weft yarns. Further, in some embodiments, the abrasive composition can be disposed through the fabric between the yarns from a first side of the fabric to a second side of the fabric.
  • the plurality of fabric layers 104 comprises a nonwoven fabric.
  • nonwoven fabric refers to a web having a structure of individual fibers that are interlaid, but not in an identifiable manner such in a knitted fabric.
  • the nonwoven fabric may comprise a spunbond fabric (also known as a “spunlaid” fabric) of spunbonded fibers, a meltblown fabric of meltblown fibers, or a combination thereof.
  • the abrasive composition may be disposed at least partially within or between the fibers of the nonwoven web. Further, in some embodiments, the abrasive composition may be disposed through the nonwoven fabric between the fibers of the web from a first side of the fabric to a second side of the fabric.
  • the fixed abrasive buff 100 is generally formed by a plurality of fabric layers 104 .
  • the fixed abrasive buff 100 may comprise at least 2 layers, at least 4 layers, at least 6 layers, at least 8 layers, at least 10 layers, at least 12 layers, at least 15 layers, at least 20 layers, or at least 25 layers.
  • the fixed abrasive buff 100 may comprise not greater than 100 layers, not greater than 50 layers, not greater than 25 layers, not greater than 20 layers, not greater than 15 layers, or not greater than 12 layers.
  • the fixed abrasive buff 100 may comprise may comprise a plurality of fabric layers 104 between any of these minimum and maximum values, such as at least 2 layers to not greater than 30 layers.
  • the abrasive composition 106 may generally comprise a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder.
  • the abrasive composition 106 may generally be disposed throughout or embedded within the plurality of fabric layers 104 , such that the abrasive composition 106 (including the abrasive particles) penetrates into and between the fibers of each of the plurality of fabric layers 104 of the fixed abrasive buff 100 .
  • the abrasive composition 106 may be applied to the fixed abrasive buff 100 and comprise a beneficial add-on weight.
  • the add-on weight of the abrasive composition 106 may be at least 15 grams, at least 16 grams, at least 17 grams, at least 18 grams, at least 19 grams, at least 20 grams, at least 21 grams, at least 22 grams, at least 23 grams, at least 24 grams, or at least 25 grams.
  • the polymeric binder may generally be formed from a single polymer or a blend of polymers.
  • the polymeric binder may be formed from an epoxy composition, acrylic composition, a phenolic composition, a polyurethane composition, a phenolic composition, a polysiloxane composition, an acrylic latex composition, a thermoset rubber composition, a thermoset elastomer composition, a styrene butadiene rubber composition, an acrylonitrile-butadiene rubber composition, a polybutadiene composition, or a combination thereof.
  • the polymeric binder may comprise a self-crosslinking carboxylated styrene-butadiene composition.
  • the polymeric binder may comprise a carboxylated acrylic composition.
  • the polymeric binder may include one or more active filler particles, additives, one or more reaction constituents or polymer constituents, thickeners, solvents, plasticizers, chain transfer agents, catalysts, defoamers, stabilizers, dispersants, curing agents, rheology modifiers, reaction mediators and agents for influencing the fluidity of the dispersion, or any combination thereof.
  • the polymeric binder may be flexible after curing such that the plurality of fabric layers 104 has a “soft” hand, also known as a soft “drape”, so that the plurality of fabric layers 104 feels soft to the touch, is flexible, and conformable around a workpiece.
  • the polymeric binder can comprise a desirable glass transition temperature (T g ) that can contribute to beneficial abrasive properties.
  • the polymeric binder may comprise a glass transition temperature of at least ⁇ 30° C., at least ⁇ 25° C., at least ⁇ 20° C., or at least ⁇ 15° C.
  • the polymeric binder may comprise a glass transition temperature of not greater than 60° C., not greater than 50° C., not greater than 40° C., not greater than 30° C., not greater than 20° C., not greater than 10° C., not greater than 0° C., or not greater than ⁇ 1° C.
  • the polymeric binder may comprise a glass transition temperature between any of these minimum and maximum values, such as at least ⁇ 30° C. to not greater than 30° C.
  • the amount of polymeric binder in the abrasive composition may vary.
  • the abrasive composition may comprise at least 10 wt. % polymeric binder, at least 15 wt. %, at least 20 wt. %, at least 25 wt. %, at least 35 wt. %, or at least 50 wt. % polymeric binder.
  • the abrasive composition may comprise not greater than 80 wt. % polymeric binder, not greater than 75 wt. %, not greater than 70 wt. %, not greater than 65 wt. %, not greater than 60 wt. %, not greater than 55 wt.
  • the amount of polymeric binder in the abrasive composition may be between any of these minimum and maximum values, such as at least 10 wt. % to not greater than 80 wt. % polymeric binder.
  • the abrasive particles may include essentially single-phase inorganic materials, such as alumina, silicon carbide, silica, ceria, and/or harder, high performance superabrasive particles such as cubic boron nitride and diamond. Further, the abrasive particles may include engineered abrasives including macrostructures and particular three-dimensional structures. Aggregates may comprise abrasive aggregates and/or nonabrasive aggregates.
  • aggregates may include composite particulate materials, which can be formed through slurry processing pathways that include removal of the liquid carrier through volatilization or evaporation, leaving behind unfired (“green”) aggregates, that can optionally undergo high temperature treatment (i.e., firing, sintering) to form usable, fired aggregates.
  • green aggregates unfired aggregates
  • the abrasive particles may be formed of any one of or a combination of abrasive particles, including silica, alumina (fused or sintered), zirconia, zirconia/alumina oxides, zirconium silicate, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery, or a combination thereof.
  • the abrasive particles and/or aggregates may be selected from a group consisting of silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, and a blend thereof.
  • the abrasive particles consist essentially of silicon carbide.
  • the average particle size of the abrasive particles may vary.
  • the particle size of the abrasive particles is typically specified to be the longest dimension of the abrasive particle. Generally, there is a range distribution of particle sizes.
  • the abrasive particles may comprise an average particle size of at least 5 micrometers, at least 10 micrometers, at least 15 micrometers, at least 20 micrometers, or at least 25 micrometers.
  • the abrasive particles may comprise an average particle size of not greater than 1500 micrometers, not greater than 1000 micrometers, not greater than 750 micrometers, not greater than 500 micrometers, not greater than 250 micrometers, not greater than 100 micrometers, or not greater than 50 micrometers. Further, it will be appreciated that abrasive particles may comprise an average particle size between any of these minimum and maximum values, such as 5 micrometers to not greater than 1500 micrometers, or even at least 10 micrometers to not greater than 50 micrometers.
  • the amount of abrasive particles in the abrasive composition may also vary.
  • the abrasive composition may comprise least 10 wt. % abrasive particles, at least 15 wt. %, at least 20 wt. %, at least 25 wt. %, at least 30 wt. %, at least 35 wt. %, at least 40 wt. %, at least 45 wt. %, at least 50 wt. %, at least 55 wt. %, or at least 60 wt. % abrasive particles.
  • the abrasive composition may comprise not greater than 75 wt.
  • % abrasive particles not greater than 70 wt. %, not greater than 65 wt. %, not greater than 60 wt. %, not greater than 55 wt. %, or not greater than 50 wt. % abrasive particles.
  • the abrasive particles can be within a range of any minimum or maximum value noted above. Further, it will be appreciated that the amount of abrasive particles in the abrasive composition may be between any of these minimum and maximum values, such as at least 10 wt. % to not greater than 75 wt. % abrasive particles.
  • Sample fixed abrasive buffs were prepared according to methods disclosed herein. Two different abrasive compositions were used. The first uncured abrasive composition is shown in Table 1 below. While ranges are provided for some components, the components in the composition total 100%.
  • the second uncured abrasive composition is shown in Table 2 below. It will be noted that the second abrasive composition comprises about 50% fewer abrasive particles. While ranges are provided for some components, the components in the composition total 100%.
  • Sample fixed abrasive buff, S1 was prepared according to methods disclosed herein, which included applying pressure to the plurality of fabric layers to cause the plurality of fabric layers to splay, and rotating the buff within the abrasive composition to coat the buff with the first abrasive composition.
  • Control sample, C1 was prepared according to conventional methods without applying pressure to the plurality of fabric layers. The resulting weights of the samples are shown in Table 3 below.
  • Sample S1 had higher weights of the abrasive composition than did the control sample C1. This can be attributed, at least in part, to the application of pressure to the plurality of fabric layers that caused the plurality of fabric layers to splay.
  • Control sample (“C1”) remained uncoated with an abrasive composition, and instead used an abrasive buffing compound that was externally applied to the buff at 6000-7000 SFPM during buffing.
  • the used control sample C1 is shown after buffing in FIG. 5A .
  • Sample S1 was prepared using the same cotton fabric buff and was coated according to methods disclosed herein with the first abrasive composition in Table 1. Used sample S1 is shown after buffing in FIG. 5B .
  • the samples (C1, S1) were tested on brass panels that were 6 inches wide, 24 inches long, and 0.125 inches thick.
  • the resultant brass panel buffed by C1 is shown in FIG. 6A .
  • the resultant brass panel buffed by S1 is shown in FIG. 6B .
  • the surface finish buffed by S1 appears to have a better surface finish.
  • FIG. 7 shows a chart providing comparative data of surface finish (Ra) of C1 and the S1. Most notably, S1 achieved a much better surface finish (Ra).
  • FIG. 8 shows a chart providing comparative data of surface finish (Rz) of C1 and the S1. Most notably, S1 achieved a much better surface finish (Rz).
  • FIG. 9 shows a chart providing comparative data of cumulative material removal (measured in grams) of C1 and S1. Most notably, S1 had a much higher cumulative material removal. Surprisingly and beneficially, S1 outperformed C1 in both surface finish (both Ra and Rz) and cumulative material removal rate.
  • Control sample, C2 utilized a woven cotton buff and remained uncoated with an abrasive composition.
  • Sample fixed abrasive buff, S2 utilized a nonwoven buff and remained uncoated with an abrasive compound.
  • Sample fixed abrasive buff, S3, utilized a nonwoven buff and was prepared according to methods disclosed herein, which included applying pressure to the plurality of fabric layers to cause the plurality of fabric layers to splay, and rotating the buff within the abrasive composition to coat the buff with the first abrasive composition.
  • Samples C2, C3, S2, and S3 were tested on substantially similar brass workpieces.
  • C2 and S2 were tested utilizing a bar compound applied to the buffs during buffing.
  • C3 and S3 were tested as prepared.
  • FIG. 10 shows a chart providing comparative data of surface finish (Ra) of C2, C3, S2, and S3. Most notably, S3 achieved a much better surface finish (Ra) as compared to C2, C3, and S2. Additionally, S3 also achieved the better surface finish in a much shorter time as compared to C2, C3, and S2.
  • FIG. 11 shows a chart providing comparative data of surface finish (Rz) of C2, C3, S2, and S3. Most notably, S3 achieved a much better surface finish (Rz) as compared to C2, C3, and S2. Additionally, S3 also achieved the better surface finish in a much shorter time as compared to C2, C3, and S2.
  • FIG. 12 shows a chart providing comparative data of cumulative material removal (measured in grams) of C2, C3, S2, and S3. Most notably, S3 had a much higher cumulative material removal as compared to C2, C3, and S2.
  • FIG. 13 shows a chart providing comparative data of required power (measured in horsepower (Hp)) of C2, C3, S2, and S3.
  • S3 required much less power to achieve the desired surface finish (both Ra and Rz) while achieving a higher cumulative material removal as compared to C2, C3, and S2. Accordingly, S3 outperformed C2, C3, and S2 in both surface finish (both Ra and Rz) and cumulative material removal rate while requiring much less power to achieve these results.
  • Samples S3 was submitted for comparison of the amount of coating and abrasive grains or particles in the sample.
  • Sample strips of 0.5 inches wide (measured circumferentially) and 1.25 inches long (measured radially) were cut from the deconstructed sample S3 as shown in FIG. 14 .
  • the sample weights of the sample strips were averaged and recorded. These sample strips were analyzed by subjecting the sample strips to a so-called “burn-off” process at 450 degrees Celsius for 10 hours.
  • the outer edges had a higher overall weight and a higher overall abrasive composition coating.
  • the outer edges had a higher concentration of abrasive grains at the outer edges (0.8972 g) as compared to the concentration of abrasive grains at the inner edges (0.4289 g).
  • the outer edges contained about 52.19% higher concentration at the outer edges for the tested sample S3.
  • Embodiment 1 A fixed abrasive buff, comprising: a central hub; a plurality of fabric layers affixed to the central hub; and an abrasive composition comprising a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder, wherein a content of the abrasive particles at an outer edge of the plurality of fabric layers is higher than the content of the abrasive particles at an inner edge of the plurality of fabric layers.
  • Embodiment 2 The fixed abrasive buff of embodiment 1, wherein the content of the abrasive particles at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the content of the abrasive particles at the inner edge of the plurality of fabric layers.
  • Embodiment 3 The fixed abrasive buff of embodiment 1, wherein the add-on weight of the abrasive composition at the outer edge of the plurality of fabric layers is higher than the add-on weight of the abrasive composition at the inner edge of the plurality of fabric layers.
  • Embodiment 4 The fixed abrasive buff of embodiment 3, wherein the add-on weight of the abrasive composition at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the add-on weight of the abrasive composition at the inner edge of the plurality of fabric layers.
  • Embodiment 5 The fixed abrasive buff of embodiment 1, wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is higher than the total weight at the inner edge of the plurality of fabric layers.
  • Embodiment 6 The fixed abrasive buff of embodiment 5, wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the total weight at the inner edge of the plurality of fabric layers.
  • Embodiment 7 The fixed abrasive buff of any of embodiments 1 to 6, wherein the inner edge is adjacent the central hub, and wherein the outer edge is radially furthest from the central hub.
  • Embodiment 8 The fixed abrasive buff of embodiment 1, wherein the plurality of fabric layers comprises a woven fabric, a nonwoven fabric, or a combination thereof.
  • Embodiment 9 The fixed abrasive buff of embodiment 8, wherein the plurality of fabric layers comprises at least 2 layers, at least 4 layers, at least 6 layers, at least 8 layers, at least 10 layers, at least 12 layers, at least 15 layers, at least 20 layers, or at least 25 layers to not greater than 100 layers, not greater than 50 layers, not greater than 25 layers, not greater than 20 layers, not greater than 15 layers, or not greater than 12 layers.
  • Embodiment 10 The fixed abrasive buff of embodiment 1, wherein the abrasive composition is dispersed on or in each of the plurality of fabric layers.
  • Embodiment 11 The fixed abrasive buff of embodiment 1, wherein the abrasive composition comprises: 10 wt. % to 80 wt. % of the polymeric binder; and 20 wt. % to 90 wt. % of abrasive particles.
  • Embodiment 12 The fixed abrasive buff of embodiment 11, wherein the polymeric binder comprises a self-crosslinking carboxylated styrene-butadiene composition.
  • Embodiment 13 The fixed abrasive buff of embodiment 11, wherein the abrasive particles comprise silicon carbide.
  • Embodiment 14 The fixed abrasive buff of embodiment 13, wherein the abrasive particles comprise an average particle size of at least 5 micrometers, at least 10 micrometers, at least 15 micrometers, at least 20 micrometers, or at least 25 micrometers.
  • Embodiment 15 The fixed abrasive buff of embodiment 14, wherein the abrasive particles comprise an average particle size of not greater than 500 micrometers, not greater than 250 micrometers, not greater than 100 micrometers, or not greater than 50 micrometers.
  • Embodiment 16 A method of forming a fixed abrasive buff, comprising: providing an uncoated buff comprising a central hub and a plurality of fabric layers affixed to the central hub; applying pressure to the plurality of fabric layers to cause the plurality of fabric layers to splay; and rotating the buff within an abrasive composition to coat the buff with the abrasive composition.
  • Embodiment 17 The method of embodiment 16, wherein a content of the abrasive particles at an outer edge of the plurality of fabric layers is higher than the content of the abrasive particles at an inner edge of the plurality of fabric layers.
  • Embodiment 18 The method of embodiment 17, wherein the content of the abrasive particles at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the content of the abrasive particles at the inner edge of the plurality of fabric layers.
  • Embodiment 19 The method of any of embodiments 16 to 18, wherein the add-on weight of the abrasive composition at the outer edge of the plurality of fabric layers is higher than the add-on weight of the abrasive composition at the inner edge of the plurality of fabric layers.
  • Embodiment 20 The method of embodiment 19, wherein the add-on weight of the abrasive composition at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the add-on weight of the abrasive composition at the inner edge of the plurality of fabric layers.
  • Embodiment 21 The method of any of embodiments 16 to 20, wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is higher than the total weight at the inner edge of the plurality of fabric layers.
  • Embodiment 22 The method of embodiment 21, wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the total weight at the inner edge of the plurality of fabric layers, or a combination thereof.
  • Embodiment 23 The method of any of embodiments 16 to 22, applying pressure to the plurality of fabric layers is accomplished by applying pressurized air towards the plurality of fabric layers, pressing the plurality of fabric layers against a sidewall of a container holding the abrasive composition, or a combination thereof.
  • Embodiment 24 The method of any of embodiments 16 to 23, further comprising: removing the fixed abrasive buff from the abrasive composition; rotating the fixed abrasive buff to spin off excess abrasive composition; and curing the abrasive composition on the fixed abrasive buff.
  • Embodiment 25 The fixed abrasive buff of any of embodiments 1 to 15 or the method of any of embodiments 16 to 24, wherein an add-on weight of the abrasive composition is at least 15 grams, at least 16 grams, at least 17 grams, at least 18 grams, at least 19 grams, at least 20 grams, at least 21 grams, at least 22 grams, at least 23 grams, at least 24 grams, or at least 25 grams.
  • the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion.
  • a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus.
  • “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
US17/212,091 2020-04-07 2021-03-25 Fixed abrasive buff Pending US20210308833A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US17/212,091 US20210308833A1 (en) 2020-04-07 2021-03-25 Fixed abrasive buff

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202063006409P 2020-04-07 2020-04-07
US17/212,091 US20210308833A1 (en) 2020-04-07 2021-03-25 Fixed abrasive buff

Publications (1)

Publication Number Publication Date
US20210308833A1 true US20210308833A1 (en) 2021-10-07

Family

ID=77921244

Family Applications (1)

Application Number Title Priority Date Filing Date
US17/212,091 Pending US20210308833A1 (en) 2020-04-07 2021-03-25 Fixed abrasive buff

Country Status (8)

Country Link
US (1) US20210308833A1 (de)
EP (1) EP4132748A4 (de)
JP (1) JP2023521096A (de)
KR (1) KR20220156966A (de)
CN (1) CN115515752A (de)
CA (1) CA3177371A1 (de)
MX (1) MX2022012590A (de)
WO (1) WO2021206918A1 (de)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3043064A (en) * 1959-11-23 1962-07-10 Osborn Mfg Co Rotary abrading tool
US20070298697A1 (en) * 2004-09-09 2007-12-27 Louis Charmoille Floor Cleaning Pads and Preparation Thereof
US11806838B2 (en) * 2017-07-31 2023-11-07 3M Innovative Properties Company Floor pad with variable abrasive distribution

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2137201A (en) * 1937-06-28 1938-11-15 Carborundum Co Abrasive article and its manufacture
US6257973B1 (en) * 1999-11-04 2001-07-10 Norton Company Coated abrasive discs
KR100433194B1 (ko) * 2001-02-19 2004-05-28 이화다이아몬드공업 주식회사 편마모방지용 세그먼트를 갖는 연마휠
SI1877219T1 (sl) * 2005-03-15 2012-02-29 Htc Sweden Ab Postopek za vzdrĺ˝evanje trdne gladke talne povrĺ ine, ki vsebuje polimerni material
BR112014005361A2 (pt) * 2011-09-07 2017-03-28 3M Innovative Properties Co artigo abrasivo colado
US9475176B2 (en) * 2012-11-15 2016-10-25 Smith International, Inc. Sintering of thick solid carbonate-based PCD for drilling application
JP2018510787A (ja) * 2015-04-01 2018-04-19 スリーエム イノベイティブ プロパティズ カンパニー 側面カバー層を有する研磨ディスク
US20180185986A1 (en) * 2016-12-31 2018-07-05 Saint-Gobain Abrasives, Inc. Abrasive buffing articles
CA3087322C (en) * 2017-12-29 2022-10-18 Saint-Gobain Abrasives, Inc. Abrasive buffing articles

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3043064A (en) * 1959-11-23 1962-07-10 Osborn Mfg Co Rotary abrading tool
US20070298697A1 (en) * 2004-09-09 2007-12-27 Louis Charmoille Floor Cleaning Pads and Preparation Thereof
US11806838B2 (en) * 2017-07-31 2023-11-07 3M Innovative Properties Company Floor pad with variable abrasive distribution

Also Published As

Publication number Publication date
EP4132748A1 (de) 2023-02-15
EP4132748A4 (de) 2024-04-24
CN115515752A (zh) 2022-12-23
WO2021206918A1 (en) 2021-10-14
CA3177371A1 (en) 2021-10-14
MX2022012590A (es) 2022-12-07
KR20220156966A (ko) 2022-11-28
JP2023521096A (ja) 2023-05-23

Similar Documents

Publication Publication Date Title
JP5764261B2 (ja) 延長された寿命を備えた不織研磨品
CN102811840B (zh) 用于涂覆的磨料的非磨蚀性背涂层
EP3370919A1 (de) Schleifartikel und verfahren zur herstellung davon
US20060026905A1 (en) Preparation of coated abrasive disk
CA2747634A1 (en) Rigid or flexible, macro-porous abrasive article
CN112041118B (zh) 低脱落非织造磨料制品
US11292102B2 (en) Abrasive buffing articles
US20120071071A1 (en) Abrasive impregnated brush
WO2016106336A1 (en) Abrasive flap wheels including hybrid fabrics
US12023783B2 (en) Abrasive articles including a blend of abrasive particles and method of forming and using the same
US20090233528A1 (en) Floor sanding sponge pads
US20210308833A1 (en) Fixed abrasive buff
US20180185986A1 (en) Abrasive buffing articles
EP3924149A1 (de) Schleifartikel und verfahren zu ihrer herstellung und verwendung
WO2019014050A1 (en) ABRASIVE ARTICLE COMPRISING A SOLUBILIZATION MATERIAL IN ANIONIC WATER AND METHOD FOR PRODUCING THE SAME
CA3107036A1 (en) Nonwoven abrasive belt with flexible joint
KR20160088920A (ko) 부직 재료를 포함하는 코팅 연마물품
KR20120037168A (ko) 그라인더형 친환경연마제품
DE102010035527A1 (de) Elastisches Schleifwerkzeug

Legal Events

Date Code Title Description
AS Assignment

Owner name: SAINT-GOBAIN ABRASIFS, FRANCE

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:RAVISHANKAR, SATHANJHERI;GOLDSMITH, PAUL S.;SYMEON, DANIEL E.;SIGNING DATES FROM 20210412 TO 20210426;REEL/FRAME:056101/0277

Owner name: SAINT-GOBAIN ABRASIVES, INC., MASSACHUSETTS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:RAVISHANKAR, SATHANJHERI;GOLDSMITH, PAUL S.;SYMEON, DANIEL E.;SIGNING DATES FROM 20210412 TO 20210426;REEL/FRAME:056101/0277

STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER

STPP Information on status: patent application and granting procedure in general

Free format text: FINAL REJECTION MAILED