WO2004048042A1 - Articles abrasifs non-tisses, procedes pour leur production et leur utilisation - Google Patents

Articles abrasifs non-tisses, procedes pour leur production et leur utilisation Download PDF

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Publication number
WO2004048042A1
WO2004048042A1 PCT/US2003/033421 US0333421W WO2004048042A1 WO 2004048042 A1 WO2004048042 A1 WO 2004048042A1 US 0333421 W US0333421 W US 0333421W WO 2004048042 A1 WO2004048042 A1 WO 2004048042A1
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WIPO (PCT)
Prior art keywords
binder
reinforcing material
abrasive
nonwoven
major surface
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Application number
PCT/US2003/033421
Other languages
English (en)
Inventor
Sherri D. Hood
Loc X. Van
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3M Innovative Properties Company
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Publication date
Application filed by 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Priority to AU2003302424A priority Critical patent/AU2003302424A1/en
Publication of WO2004048042A1 publication Critical patent/WO2004048042A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
    • B24D3/348—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties utilised as impregnating agent for porous abrasive bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/001—Manufacture of flexible abrasive materials
    • B24D11/005—Making abrasive webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0027—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for by impregnation

Definitions

  • the present invention relates to nonwoven abrasive articles.
  • Nonwoven abrasive articles typically comprise an open porous fiber web having abrasive particles bonded thereto by a binder.
  • a reinforcing scrim or fabric is typically affixed to the fiber web.
  • Such reinforced articles are known, for example, in forms such as discs and belts.
  • the reinforcing scrim or fabric is typically affixed to the fiber web by an adhesive resin and/or by mechanical means such as needletacking.
  • an elastomeric binder precursor (that is, prebond precursor) is commonly applied to the fiber web, and cured to form a prebonded reinforced fiber web.
  • abrasive nonwoven discs and belts are typically made from prebonded reinforced fiber web by one of two methods. In one method, prebonded reinforced fiber web is typically coated with a slurry of abrasive particles in a curable binder precursor (that is, slurry coat precursor), and then the binder precursor is cured to form a slurry coat on the reinforced non-woven web.
  • a curable binder precursor that is, make coat precursor
  • abrasive particles are applied to the make coat precursor
  • the make coat precursor is at least partially cured to form a make coat.
  • Another curable binder precursor that is, size coat precursor
  • an abrasive composition that is, the make coat, abrasive particles, and size coat taken collectively
  • portions of the abrasive article may detach in phenomena commonly referred to as "shelling” (that is, loss of abrasive particles) or “chunking” (that is, loss of chunks of binder, fiber web, and abrasive particles).
  • shelling that is, loss of abrasive particles
  • chunking that is, loss of chunks of binder, fiber web, and abrasive particles.
  • Chunking may be especially troublesome in the case of nonwoven abrasive endless belts.
  • Shelling and chunking are typically undesirable, as they generally degrade the performance of the nonwoven abrasive article.
  • the present invention provides a nonwoven abrasive article comprising: a porous reinforcing material having first and second opposed major surfaces; a fiber web, wherein the fiber web is affixed to the first major surface of the porous reinforcing material; and an abrasive composition comprising abrasive particles and a non-elastomeric binder, wherein the abrasive composition contacts at least a portion of the fiber web and the first major surface of the porous reinforcing material, wherein the abrasive composition extends through at least a portion of the porous reinforcing material and contacts at least a portion of the second major surface of the porous reinforcing material, and wherein, on a weight basis, there is a first average ratio of abrasive particles to the non-elastomeric binder at the first major surface, and a second average ratio of abrasive particles to the non-elastomeric binder at the second major surface, and wherein the first average ratio is
  • the present invention provides a method for making a nonwoven abrasive article comprising: providing a fiber web; providing a porous reinforcing material having first and second opposed major surfaces; affixing the fiber web to the first major surface of the reinforcing material; applying a first binder precursor and abrasive particles onto the fiber web, wherein at least a portion of the first binder precursor penetrates through the porous reinforcing material and contacts at least a portion of the first and second major surfaces; and at least partially curing the first binder precursor to form a non-elastomeric first binder, wherein on a weight basis, there is a first average ratio of abrasive particles to the non-elastomeric binder at the first major surface, and a second average ratio of abrasive particles to the non-elastomeric binder at the second major surface, and wherein the first average ratio is greater than the second average ratio.
  • the present invention provides a method of abrading a surface, the method comprising: providing a nonwoven abrasive article according to the present invention; contacting at least one of the abrasive particles of the abrasive article with the surface of the workpiece; and moving at least one of the abrasive particles or the contacted surface relative to the other to abrade at least a portion of the contacted surface.
  • Nonwoven abrasive articles typically have an acceptable level of shelling and/or chunking during use, for example, if used as an endless belt mounted onto equipment (for example, belt sander) having small diameter pulleys and/or rollers.
  • equipment for example, belt sander
  • FIG. 1 is a cross-sectional view of an exemplary nonwoven abrasive article according to the present invention
  • FIG. 2 is a cross-sectional view of another exemplary nonwoven abrasive article according to the present invention.
  • FIG. 3 is a perspective view of an exemplary nonwoven abrasive disc according to one embodiment of the present invention
  • FIG. 4 is a perspective view of an exemplary endless nonwoven abrasive belt according to one embodiment of the present invention.
  • exemplary nonwoven abrasive article according to the present invention 100 comprises fiber web 110 affixed to porous reinforcing material 120 of thickness 185 and having first and second opposed major surfaces 122 and 124, respectively.
  • Slurry coat 130 comprising abrasive particles 135 and non-elastomeric binder 138, contacts at least a portion of fiber web 110 and first major surface 122 of porous reinforcing material 120.
  • Optional size coat 170 contacts slurry coat 130, porous reinforcing material 120, fiber web 110, and fibers 192.
  • Non-elastomeric binder 138 extends through at least a portion of porous reinforcing material 120, and contacts at least portion of second major surface 124 of porous reinforcing material 120.
  • the average ratio on a weight basis of abrasive particles 135 to non-elastomeric binder 138 is higher at first major surface 122 than at second major surface 124.
  • zone 180a which is the combination of zones 187a and 189a.
  • Zone 187a is the outer 20 percent of thickness 185 that contacts first major surface 122.
  • Zone 189a which has the same thickness as zone 187a, contacts zone 187a, and extends beyond first major surface 122.
  • the phrase "at the second surface” is to be construed as referring to zone 180b, which is the combination of zones 187b and 189b.
  • Zone 187a is the outer 20 percent of thickness 185 that contacts first major surface 124.
  • Zone 189b which has the same thickness as zone 187b, contacts zone 187b, and extends beyond first major surface 124.
  • nonwoven abrasive article 200 comprises fiber web 110 affixed to porous reinforcing material 120 of thickness 185 and having first and second opposed major surfaces 122 and 124, respectively.
  • Make coat 230 comprising non-elastomeric binder 138, has abrasive particles 135 bonded thereto, and contacts at least a portion of fiber web 110 and first major surface 122 of porous reinforcing material 120.
  • Optional size coat 170 contacts make coat 230, abrasive particles 135, porous reinforcing material 120, fiber web 110, and fibers 192.
  • Non-elastomeric binder 138 extends through a portion of porous reinforcing material 120 and contacts a portion of second major surface 124 of porous reinforcing material 120.
  • the average ratio on a weight basis of abrasive particles 135 to non- elastomeric binder 138 is higher at first major surface 122 than at second major surface 124.
  • the fiber web comprises an entangled web of fibers (that is, a fibrous nonwoven).
  • fibers that is, a fibrous nonwoven.
  • the fiber web may be made, for example, by conventional air laid, carded, stitch bonded, spun bonded, wet laid, and/or melt blown procedures. Air laid fiber webs may be prepared using equipment such as, for example, that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Ard, New York.
  • the fiber web Prior to affixing the fiber web to the porous reinforcing material, the fiber web is typically open (for example, lofty and open). After affixing the fiber web to the porous reinforcing material, depending on the method used (for example, needletacking), the fiber web may be denser and thinner.
  • the fiber web is selected to be suitably compatible with adhering binders and abrasive particles while also being processable in combination with other components of the article (for example, binder precursors, hardened binders, abrasive materials), and typically can withstand temperatures at which such binder precursors and other materials are applied and processed.
  • the fiber may be chosen to affect properties of the abrasive article such as flexibility, elasticity, durability or longevity, abrasiveness, and finishing properties.
  • Examples of fibers that may be suitable include natural fibers, synthetic fibers, and mixtures of natural and/or synthetic fibers.
  • polyester for example, polyethylene terephthalate
  • nylon for example, hexamethylene adipamide, polycaprolactam
  • polypropylene acrylic (formed from a polymer of acrylonitrile), rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymers, vinyl chloride-acrylonitrile copolymers, and so forth.
  • Suitable natural fibers include cotton, wool, jute, and hemp.
  • the fiber may be of virgin materials or of recycled or waste materials reclaimed from garment cuttings, carpet manufacturing, fiber manufacturing, or textile processing, for example.
  • the fiber may be homogenous or a composite such as a bicomponent fiber (for example, a co-spun sheath- core fiber).
  • the fibers may be tensilized and crimped, but may also be continuous filaments such as those formed by an extrusion process. It is also within the scope of the invention to provide an article comprising different fibers in different portions of the nonwoven (for example, at a first major surface, a second major surface, and within the middle portion therebetween).
  • the fiber web may comprise staple fibers having a length of at least 20 millimeters (mm), at least 30 mm, or at least 40 mm, and less than 110 mm, less than 85 mm, or less than 65 mm, although shorter and longer fibers (for example, continuous filaments) may also be useful.
  • the fibers may have a fineness or linear density of at least 1.7 decitex (dtex), at least 6 dtex, or at least 7 dtex, and less than 560 dtex, less than 280 dtex, or less than 120 dtex, although fibers having lesser and/or greater linear densities may also be useful.
  • the filaments may be of substantially larger diameter, for example, up to 2 mm or more in diameter.
  • the fiber web may optionally be reinforced and/or consolidated by any of various methods known and understood in the art of nonwoven materials, including thermal or chemical bonding, hydroentanglement, and the like.
  • the fiber web typically has a weight per unit area (that is, basis weight) of at least about 50 grams per square meter (g/m ⁇ ), at least 100 g/m ⁇ , or at least 200 g/m ⁇ ; and/or less than 400 g/m ⁇ , less than 350 g/m ⁇ , or less than 300 g/m ⁇ , as measured prior to any coating (for example, prior to application of any binder precursors), although greater and lesser basis weights may also be used.
  • basis weight that is, basis weight
  • the fiber web typically has a thickness of at least 5 mm, at least 6 mm, or at least 10 mm; and/or less than 200 mm, less than 75 mm, or less than 30 mm, although greater and lesser thicknesses may also be useful.
  • the reinforcing material may be affixed to the nonwoven by methods that are useful or known in the art of nonwoven materials, using conventional materials such as adhesives and needletacking techniques.
  • a porous reinforcing material may be contacted with a surface of the nonwoven material before needletacking.
  • the nonwoven is typically needletacked while contacting the porous reinforcing material, such that fibers of the nonwoven are pushed or pulled from the first major surface of the porous reinforcing material, through the porous reinforcing material, and extend outwardly out from the second major surface.
  • needletacking is generally preferred. Needletacking processes are well known in the art of nonwoven materials, and are readily accomplished by use of conventional needle loom equipment commercially available, for example, from Dilo, Charlotte, North Carolina or DOA, Linz, Austria.
  • the properties of the reinforcing material may also influence physical properties of an abrasive article prepared therefrom, including stiffness, flexibility, durability, etc.
  • the porous reinforcing material may comprise a porous dimensionally stable, woven, fibrous material (for example, scrim).
  • the porous reinforcing material should typically be capable of withstanding processing into an abrasive article as described herein, and is preferably stable at temperatures at which binder precursors are applied and/or processed.
  • the term "porous" as applied herein to the reinforcing material means that the reinforcing material is sufficiently porous that a binder precursor (for example, slurry coat precursor, make coat precursor) may penetrate through the thickness of the reinforcing material.
  • the reinforcing material may be a woven stretch-resistant fabric, and may have tensile strain in at least one direction of less than 5 percent stretch or less than 2.5 percent stretch, at tensile loads up to 100 pounds/inch (174 N/cm).
  • Suitable reinforcing materials include, for example, thermo-bonded fabrics, knitted fabrics, stitch-bonded fabrics.
  • the reinforcing material may include fibers of nylon and/or polyester.
  • the second major surface of the porous reinforcing material may be coated with a thermoplastic polymer or thermosetting resin to encapsulate outwardly extending fibers and provide a smooth surface as described, for example, in U.S. Pat. No. 5,482,756 (Berger et al.
  • thermoplastic polymer or thermosetting resin is typically applied after any coatings (for example, make, size, slurry, and/or supersize) have been applied, in order that the backing is at least partially permeable to such coatings.
  • Any binder precursor used in preparation of the abrasive composition (for example, slurry coat precursor, make coat precursor) is typically applied to the fiber web after it is affixed to the porous reinforcing material.
  • the binder precursor is typically applied to the fiber web in liquid form (for example, by conventional methods), and subsequently hardened (for example, at least partially cured) to form a layer coated on at least a portion of the fiber web and porous reinforcing material.
  • a slurry coat precursor comprising abrasive particles and a first binder precursor is applied to the fiber web and the first major surface of the porous reinforcing material, and then at least partially cured.
  • the first binder precursor component diffuses through at least a portion of the porous reinforcing material (that is, from the first major surface of porous reinforcing material to at least a portion of the second major surface of the reinforcing material).
  • a second binder precursor that is, a size coat precursor
  • a size coat precursor which may be the same as or different from the slurry coat precursor may be applied to the slurry coat, typically after at least partially curing the slurry coat precursor.
  • a make coat precursor comprising a first binder precursor is typically applied to the fiber web, abrasive particles are deposited on the make coat, and then the make coat precursor is hardened (for example, by evaporation, cooling, and/or at least partially curing).
  • the make coat precursor diffuses through at least a portion of the porous reinforcing material (that is, from the first major surface of porous reinforcing material to at least a portion of the second major surface of the reinforcing material).
  • a second binder precursor that is, a size coat precursor
  • a second binder precursor that is, a size coat precursor
  • binder precursors employed in slurry coat precursors or at least one of make coat precursors and/or size coat precursors (for example, as described above), comprise a monomeric or polymeric material that may be at least partially cured (that is, polymerized and/or crosslinked).
  • such binder precursors upon at least partial curing, form a non-elastomeric binder (for example, a hard brittle binder) that may have a Knoop hardness number (KHN, expressed in kgf/mm ⁇ ) of, for example, at least 20, at least 40, at least 60, or at least 80 as measured in accordance with ASTM Test Method D 1474-98(2002) "Standard Test Methods for Indentation Hardness of Organic Coatings”) that bonds abrasive particles to the fiber web.
  • KHN Knoop hardness number
  • Examples of binder precursors that may be at least partially cured to form a non- elastomeric binder material include condensation curable materials and/or addition polymerizable materials.
  • binder precursors may be solvent based, water based, or 100 percent solids.
  • Exemplary binder precursors include phenolic resins, bismaleimides, vinyl ethers, aminoplasts, urethanes, epoxy resins, acrylates, acrylated isocyanurates, urea- formaldehyde resins, isocyanurates, acrylated urethanes, acrylated epoxies, or mixtures of any of the foregoing.
  • Phenolic resins and epoxy resins, and combinations thereof, are among preferred binder precursors due to their high performance, wide availability, and low cost.
  • Exemplary phenolic resins suitable for use in binder precursors include resole phenolic resins and novolac phenolic resins.
  • Exemplary commercially available phenolic materials include those having the trade designations "DUREZ” or “VARCUM” (available from Occidental Chemical Corporation, Dallas, Texas); “RESINOX” (available from Monsanto Company, St. Louis, Missouri); “AROFENE” or “AROTAP” (available from Ashland Chemical Company, Columbus, Ohio); and “BAKELITE” from Dow Chemical
  • Exemplary epoxy resins include the diglycidyl ether of bisphenol A, as well as materials that are commercially available under the trade designations "EPON” (for example, “EPON 828", “EPON 1004", and “EPON 1001F”) from Shell Chemical Co., Houston, Texas; and under the trade designations "DER” (for example, “DER-331”, “DER-332", and “DER-334") or "DEN” (for example, "DEN-431” and "DEN-428”) from Dow Chemical Company, Midland, Michigan.
  • EPON for example, "EPON 828", “EPON 1004", and "EPON 1001F”
  • DER for example, "DER-331”, “DER-332”, and "DER-334”
  • DEN for example, "DEN-431” and "DEN-428
  • Exemplary urea-formaldehyde resins and melamine-formaldehyde resins include those commercially available under the trade designation "UFORMITE” (for example, from Reichhold Chemical, Durham, North Carolina); “DURITE” (from Borden Chemical Company, Columbus, Ohio); and “RESIMENE” (for example, from Monsanto, St. Louis, Missouri).
  • UFORMITE for example, from Reichhold Chemical, Durham, North Carolina
  • DURITE from Borden Chemical Company, Columbus, Ohio
  • RESIMENE for example, from Monsanto, St. Louis, Missouri
  • Suitable methods for applying slurry coat precursors, make coat precursors, size coat precursors, etc. are well known in the art of nonwoven abrasive articles, and include coating methods such as curtain coating, roll coating, spray coating, and the like.
  • spray coating is an effective and economical method for applying slurry coat and make coat precursors. Exemplary slurry coating techniques are described, for example, in U.
  • a slurry coat precursor or make coat precursor is applied to the fiber web and porous reinforcing material.
  • the slurry coat precursor or make coat precursor typically penetrates into pores of a first major surface of the porous reinforcing material, and extends through at least a portion of the porous reinforcing material (as opposed to mere edge contact), emerging at the second major surface of the porous reinforcing material.
  • abrasive particles that are present in the slurry coat precursor are typically at least partially filtered out such that the average ratio of abrasive particles to binder precursor is substantially higher at the first major surface of the porous reinforcing material than at the second major surface.
  • the average ratio of abrasive particles to binder precursor at the first major surface may be at least 2, at least 10, at least 50, or a least 100 times the average ratio of abrasive particles to binder precursor at the second major surface.
  • the optional size coat may be elastomeric or non-elastomeric and may contain various additives such as, for example, one or more of a lubricant and/or a grinding aid.
  • the optional size coat may comprise an elastomer (for example, a polyurethane elastomer).
  • exemplary useful elastomers include those known for use as a size coat for nonwoven abrasive articles.
  • elastomers may be derived from isocyanate- terminated urethane prepolymers such as, for example, those commercially available under the trade designations "VIBRATHANE” or “ADIPRENE” from Crompton & Knowles Corporation, Middlebury, Connecticut; and "MONDUR” or “DESMODUR” from Bayer Corporation, Pittsburgh, Pennsylvania.
  • the slurry coat, make coat, and/or size coat may further include one or more catalysts and/or curing agents to initiate and/or accelerate the curing process (for example, thermal catalyst, hardener, crosslinker, photocatalyst, thermal initiator, photoinitiator) as well as in addition, or alternatively, other known additives such as fillers, thickeners, tougheners, grinding aids, pigments, fibers, tackifiers, lubricants, wetting agents, surfactants, antifoaming agents, dyes, coupling agents, plasticizers, suspending agents, and the like.
  • exemplary lubricants include metal stearate salts such as lithium stearate and zinc stearate, or materials such as molybdenum disulfide, and mixtures thereof.
  • grinding aid refers to a non-abrasive (for example, having a Mohs hardness of less than 7) particulate material that has a significant effect on the chemical and physical processes of abrading. In general, the addition of a grinding aid increases the useful life of a nonwoven abrasive.
  • Exemplary grinding aids include inorganic and organic materials, include waxes, organic halides (for example, chlorinated waxes, polyvinyl chloride), halide salts (for example, sodium chloride, potassium cryolite, cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, magnesium chloride), metals (for example, tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium and their alloys), sulfur, organic sulfur compounds, metallic sulfides, graphite, and mixtures thereof.
  • organic halides for example, chlorinated waxes, polyvinyl chloride
  • halide salts for example, sodium chloride, potassium cryolite, cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, magnesium chloride
  • metals for example, t
  • Binder precursors utilized in practice according to the present invention may typically be cured by exposure to, for example, thermal energy (for example, by direct heating, induction heating, and/or by exposure to microwave and/or infrared electromagnetic radiation) and/or actinic radiation (for example, ultraviolet light, visible light, particulate radiation).
  • thermal energy for example, by direct heating, induction heating, and/or by exposure to microwave and/or infrared electromagnetic radiation
  • actinic radiation for example, ultraviolet light, visible light, particulate radiation.
  • Exemplary sources of thermal energy include ovens, heated rolls, and infrared lamps.
  • Abrasive particles suitable for use in abrasive compositions utilized in practice according to the present invention include any abrasive particles known in the abrasive art.
  • Exemplary useful abrasive particles include fused aluminum oxide based materials such as aluminum oxide, ceramic aluminum oxide (which may include one or more metal oxide modifiers and/or seeding or nucleating agents), and heat-treated aluminum oxide, silicon carbide, co-fused alumina-zirconia, diamond, ceria, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, emery, sol-gel derived abrasive particles, and mixtures thereof.
  • fused aluminum oxide based materials such as aluminum oxide, ceramic aluminum oxide (which may include one or more metal oxide modifiers and/or seeding or nucleating agents), and heat-treated aluminum oxide, silicon carbide, co-fused alumina-zirconia, diamond, ceria, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, emery, sol-gel derived abrasive particles, and mixtures thereof.
  • the abrasive particles comprise fused aluminum oxide, heat-treated aluminum oxide, ceramic aluminum oxide, silicon carbide, alumina zirconia, garnet, diamond, cubic boron nitride, sol-gel derived abrasive particles, or mixtures thereof.
  • sol-gel abrasive particles include those described U. S. Pat. Nos. 4,314,827 (Leitheiser et al.); 4,518,397 (Leitheiser et al.); 4,623,364 (Cottringer et al.); 4,744,802 (Schwabel);
  • the abrasive particles may be in the form of, for example, individual particles, agglomerates, composite particles, and mixtures thereof.
  • Exemplary agglomerates and composite particles are described, for example, inU. S. Pat. Nos. 4,652,275 (Bloecher et al.); 4,799,939 (Bloecher et al.); 5,549,962 (Holmes et al.).
  • the abrasive particles may, for example, have an average diameter of at least 0.1 micrometer, at least 1 micrometer, or at least 10 micrometers, and less than 2000, less than 1300 micrometers, or less than 1000 micrometers, although larger and smaller abrasive particles may also be used. Coating weights for the abrasive particles may depend, for example, on the binder precursor used, the process for applying the abrasive particles, and the size of the abrasive particles.
  • the coating weight of the abrasive particles may be at least 200 grams per square meter (g/m 2 ), at least 600 g/m 2 , or at least 800 g/m 2 ; and/or less than 2000 g/m 2 , less than 1600 g/m 2 , or less than 1200 g/m 2 , although greater or lesser coating weights may be also be used.
  • Abrasive particles may be applied to a fiber web having a make coat thereon by methods known in the abrasive art for application of such particles.
  • the abrasive particles may be applied to the make coat by blowing, dropping, electrostatically coating the particles onto uncured binder precursor, or by a combination thereof.
  • the fiber web is affixed to the porous reinforcing material by needletacking, the optional prebond may be applied, for example, after the needletacking step.
  • a supersize may be present as a continuous or discontinuous layer in contact with at least a portion of the abrasive composition.
  • additional coatings for example, a supersize
  • a supersize may be present as a continuous or discontinuous layer in contact with at least a portion of the abrasive composition.
  • a supersize may be desirable to include a supersize to provide, for example, a grinding aid, and/or as an anti-loading coating.
  • the supersize is typically derived from a curable binder precursor.
  • Optional supersize may be applied by methods well known in the abrasive arts, for example, by spraying or metered roll coating. Further details concerning supersizes may be found, for example, in U. S. Pat. Nos.
  • Nonwoven abrasive articles according to the present invention may be used in sheet form, stacked together with or without additional adhesive or binder to form a wheel or brush product, or may be further processed to provide finished articles (for example, hand pads, discs, endless belts) suitable for use in surface finishing applications.
  • nonwoven abrasive disc 300 having optional center arbor hole 310 therein, is formed from nonwoven abrasive article 100.
  • Nonwoven abrasive discs having a diameter in a range of from 2 centimeters (cm) to 20 cm may typically be used with a right-angle power tool having a suitable attachment means (for example, via a center arbor hole, pressure-sensitive adhesive, "hook-and-loop” or another type of mechanical fastener).
  • nonwoven abrasive endless belt 400 comprises a strip of nonwoven abrasive material 100 joined at both ends by splice 410, such that fiber web 110 is outwardly disposed.
  • strips are typically cut having a length and a width suitable for the formation of endless belts that will fit, for example, on an abrasive belt sander.
  • Conventional splicing techniques may be used to form the finished belt.
  • One such technique known as a butt splice, generally requires that the ends of the composite strips be angled in a mating configuration, and the ends may then be spliced using a conventional urethane splicing adhesive and a heated belt splicing technique.
  • other belt forming materials and techniques may be used such as conventional nonwoven abrasive belt manufacturing techniques and adhesives.
  • endless belts according to the present invention may be mounted on a conventional belt sander.
  • endless belts typically travel around wheels that may be small in diameter, which in turn may cause the belt to chunk.
  • Nonwoven abrasive articles according to the present invention typically have acceptable levels of chunking and are well suited for use as endless belts.
  • Nonwoven abrasive articles according to the present invention are typically useful for abrading a workpiece.
  • One such method includes frictionally contacting a nonwoven abrasive article with a surface of the workpiece, and moving at least one of the nonwoven abrasive article or the workpiece relative to the other to abrade at least a portion of the surface.
  • workpiece materials include metal, metal alloys, exotic metal alloys, ceramics, glass, wood, wood-like materials, composites, painted surfaces, plastics, reinforced plastics, stone, and/or combinations thereof.
  • the workpiece may be flat or have a shape or contour associated with it.
  • Exemplary workpieces include metal components, plastic components, particleboard, camshafts, crankshafts, furniture, and turbine blades.
  • Nonwoven abrasive articles according to the present invention may be used by hand and/or used in combination with a machine.
  • Abrading may be conducted under wet or dry conditions.
  • Exemplary liquids for wet abrading include water, water containing conventional rust inhibiting compounds, lubricant, oil, soap, and cutting fluid.
  • the liquid may also contain defoamers, degreasers, and/or the like.
  • AO100-150 Brown aluminum oxide abrasive particles having the trade designation "DURALUM G52" (ANSI grade 100 - 150, 2 percent 100 grit particles, 41 percent 120 grit particles, 26 percent 140 grit particles, 17 percent 170 grit particles, and 14 percent particles finer than 170 grit) obtained from Washington Mills Electro Minerals Company
  • HTAO60 P60 grit heat-treated aluminum oxide particles obtained under the trade designation "ALODUR BFRPL” from Treibacher Schleifsch AG, Villach, Austria
  • BR2 A reaction product of one equivalent of poly(tetramethylene glycol) polymer with two equivalents of toluene diisocyanate to produce a difunctional isocyanate prepolymer that was subsequently blocked with methyl ethyl ketoxime (equivalent weight of the blocked adduct was 757) obtained under the trade designation "ADIPRENE BL-16" from Crompton & Knowles Corporation, Stamford, Connecticut
  • An endless 1/2 inch x 24 inch (1.2 cm x 61 cm) belt was mounted and maintained in tension via an air cylinder under 20 psi (140 kPa) pressure between a 2.5 inch (6.4 cm) diameter driving wheel and a 7/16 inch (1.1 cm) steel contact wheel.
  • the driving wheel was driven by a motor having the trade designation "GOLDLINE BRUSHLESS P. M. SERVOMOTOR” obtained from Kollmorgen Corporation, Waltham, Massachusetts, and operating at 7500 rpm.
  • the belt was weighed before each test, again after 1 minute, and again either after 3 minutes or at the end of belt life as determined by excessive belt stretch, whichever occurred first.
  • COMPARATIVE EXAMPLE 1 A 24-inch x 1/2-inch (61 cm x 1.2 cm) nonwoven abrasive belt obtained under the trade designation "BRITERITE RAPID CUT BELT (COARSE GRADE)" from Standard Abrasives, Simi Valley, California.
  • COMPARATIVE EXAMPLE 2 A 24-inch x 1/2-inch (61 cm x 1.2 cm) nonwoven abrasive belt obtained under the trade designation "BRITERITE RAPID CUT BELT (MEDIUM GRADE)" from Standard Abrasives.
  • COMPARATIVE EXAMPLE 3 A 7-inch (18 cm) diameter nonwoven abrasive disc obtained under the trade designation "BRITERITE RAPID CUT DISC (COARSE GRADE)" from Standard Abrasives.
  • COMPARATIVE EXAMPLE 4 A 7-inch (18 cm) diameter nonwoven abrasive disc obtained under the trade designation BRITERITE RAPID CUT DISC (MEDIUM GRADE) from Standard Abrasives.
  • COMPARATIVE EXAMPLE 5 A surface conditioning VELCRO disc (178 mm), medium grit (grit 100-120) aluminum oxide commercially available from Bibielle, Margarita, Italy.
  • the needletacking machine was operated at 560 punches per minute, a penetration depth of 2.2 cm, and at a fiber web rate of 3.1 m/minute. Needletacking affixed the fiber web to the reinforcing fabric.
  • the resultant reinforced fiber web with a total thickness of 1/4 inch (0.6 cm), had approximately 60 percent of its thickness above the center plane of the polyester reinforcing fabric and approximately 40 percent of its thickness below the center plane.
  • the composite web was then brought into contact with a roll heated at 177 °C.
  • a slurry coat precursor consisting of the ingredients in Table 1 (below) was sprayed onto the composite web at a target dry add-on weight of
  • the heated composite web was then saturated with the size coat precursor composition shown in Table 2 (below).
  • the size coat precursor saturated web was compressed between a pair of rubber rolls to remove excess size coating precursor.
  • the size composition was coated at a dry add-on weight of 627 g/m 2 , and the size-coated web was then cured for 20 minutes at 135 °C resulting in a nonwoven abrasive article.
  • EXAMPLE 2 A nonwoven abrasive article was prepared as in Example 1, except that the size coat precursor of TABLE 2 was replaced by the size coat precursor composition of Table
  • EXAMPLE 3 A nonwoven abrasive article was prepared as in Example 1, except that HTAO80 was substituted for AO80, and the size coat precursor of Table 2 was replaced with a size coat precursor having the composition given in Table 4 (below), which was applied to heated composite web at a dry add-on of 481 g/m 2 .
  • EXAMPLE 4 A nonwoven abrasive article was prepared as in Example 3, except that the size coat precursor having the composition given in Table 4 was replaced by a size coat precursor having the composition given in Table 3.
  • EXAMPLE 5 A nonwoven abrasive article was prepared as in Example 4, except that AO100- 150 was substituted for HTAO80 in the slurry coat precursor, the slurry coat dry add-on weight was 1190 g/m 2 , and the air-laid web consisted solely of 58 den (64 dtex) fibers.
  • EXAMPLE 6 A nonwoven abrasive article was prepared as in Example 1, except that the slurry coat precursor of Table 1 was replaced by a slurry coat precursor consisting of the components listed in Table 5 (below) and sprayed at a dry add-on of 1338 g/m 2 , and that the size coat precursor having the composition given in Table 2 was replaced by a size coat precursor having the composition given in Table 4, which was applied to the heated web to achieve a dry add-on weight of 481 g/m 2 and then heated for 10 minutes at 135 °C.
  • the nonwoven abrasive articles of Examples 1 - 6 were converted into endless belts (0.5 inch (1.3 cm) x 24 inches (61 cm)) endless belts as follows:
  • the nonwoven abrasive was cut into a 1/2 inch (1.3 cm) x 24 inches (61 cm), 45 parallelogram-shaped strip.
  • Two-part urethane adhesive was mixed and applied onto the same side of each end of the strip. The ends were abutted and attached together by a 1- inch (2.5 cm) splice tape. Pressure (40-60 psi (0.3 - 0.4 MPa)) was applied until the adhesive cured.
  • Mixture 7D was prepared as follows:
  • Mixture 7C (47.62 parts, at 60 °C) was stirred at sufficient speed that a vortex formed.
  • Mixture 7 A (47.62 parts, at 21 °C) was added into the vortex, and the mixture was sti ⁇ ed until it appeared homogenous.
  • Water (4.76 parts, at 49 °C) was added into the vortex, and the mixture was sti ⁇ ed until it appeared homogenous (Mixture 7D).
  • a nonwoven abrasive article was prepared as in Example 1, except that the fabric was a plain weave nylon scrim (16x16 nylon scrim; Type 6,6; Style 6703832 obtained from Highland Industries, Greensboro, North Carolina), the slurry coat precursor of Table 1 was replaced by a slurry coat precursor consisting of the components listed in Table 7
  • the resultant nonwoven abrasive article was die cut into a 7-inch diameter disc.
  • EXAMPLE 8 A nonwoven abrasive article was prepared as in Example 7, except that AO100-
  • EXAMPLE 9 A nonwoven abrasive article was prepared as in Example 7, except that size coat precursor having the composition of Mixture 7D was replaced by a size coat precursor having the composition listed in Table 8 (below), which was coated and the resultant coated article was then heated at 110 °C for 30 minutes.
  • EXAMPLE 10 A nonwoven abrasive article was prepared as in Example 9, except that AO100- 150 was substituted for AO80 in the slurry coat precursor.
  • a nonwoven abrasive article was prepared as in Example 9, except that the size coat precursor having the composition listed in Table 8 was replaced by a size coat precursor having the composition listed in Table 4.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

L'invention concerne des articles abrasifs non-tissés (100) comprenant un matériau de renforcement poreux (120), une bande fibreuse (110) fixée au matériau de renforcement poreux (120), des particules abrasives (135), et un liant non élastomère (138). L'invention concerne également des procédés pour produire et utiliser lesdits articles abrasifs non-tissés (120).
PCT/US2003/033421 2002-11-25 2003-10-22 Articles abrasifs non-tisses, procedes pour leur production et leur utilisation WO2004048042A1 (fr)

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US10/304,041 US20040098923A1 (en) 2002-11-25 2002-11-25 Nonwoven abrasive articles and methods for making and using the same

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US7329175B2 (en) * 2004-12-30 2008-02-12 3M Innovative Properties Company Abrasive article and methods of making same
BRPI0520844B1 (pt) * 2005-03-15 2021-01-19 Twister Cleaning Technology Ab método para manter uma superfície dura compreendendo uma pedra ou material tipo pedra
AU2007216871C1 (en) * 2005-03-15 2009-10-29 Twister Cleaning Technology Ab Methods and Tool for Maintenance of Hard Surfaces, and a Method for Manufacturing Such a Tool
EP1702714B1 (fr) * 2005-03-15 2007-05-09 HTC Sweden AB Procédé d'entretien des surfaces dures
US10065283B2 (en) * 2005-03-15 2018-09-04 Twister Cleaning Technology Ab Method and tool for maintenance of hard surfaces, and a method for manufacturing such a tool
US20060265966A1 (en) * 2005-05-24 2006-11-30 Rostal William J Abrasive articles and methods of making and using the same
US20060265967A1 (en) * 2005-05-24 2006-11-30 3M Innovative Properties Company Abrasive articles and methods of making and using the same
US7252694B2 (en) * 2005-08-05 2007-08-07 3M Innovative Properties Company Abrasive article and methods of making same
US7258705B2 (en) * 2005-08-05 2007-08-21 3M Innovative Properties Company Abrasive article and methods of making same
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US7393269B2 (en) * 2005-09-16 2008-07-01 3M Innovative Properties Company Abrasive filter assembly and methods of making same
US7338355B2 (en) 2006-06-13 2008-03-04 3M Innovative Properties Company Abrasive article and methods of making and using the same
JP2008087082A (ja) * 2006-09-29 2008-04-17 Three M Innovative Properties Co 吸塵用研磨具
US7985269B2 (en) * 2006-12-04 2011-07-26 3M Innovative Properties Company Nonwoven abrasive articles and methods of making the same
US7452265B2 (en) * 2006-12-21 2008-11-18 3M Innovative Properties Company Abrasive article and methods of making same
US20080233850A1 (en) * 2007-03-20 2008-09-25 3M Innovative Properties Company Abrasive article and method of making and using the same
US7628829B2 (en) * 2007-03-20 2009-12-08 3M Innovative Properties Company Abrasive article and method of making and using the same
BR112013007487B1 (pt) * 2010-10-06 2020-12-22 Saint-Gobain Abrasifs abrasivo compósito não tecido que compreende partículas abrasivas de diamante
EP2651602A1 (fr) * 2010-12-14 2013-10-23 3M Innovative Properties Company Article de polissage fibreux autonome
EP2978567B1 (fr) 2013-03-29 2023-12-27 3M Innovative Properties Company Articles abrasifs non tissés et leurs procédés de fabrication
BR112016012064A2 (pt) * 2013-12-06 2017-08-08 Saint Gobain Abrasives Inc Artigo abrasivo revestido incluindo um material não tecido
WO2017034257A1 (fr) * 2015-08-21 2017-03-02 주식회사 아모그린텍 Carte de circuit imprimé souple vestimentaire, son procédé de fabrication et dispositif intelligent vestimentaire l'utilisant
WO2018005111A1 (fr) * 2016-07-01 2018-01-04 3M Innovative Properties Company Article abrasif non tissé comprenant des particules abrasives
EP3532561B1 (fr) * 2016-10-25 2021-04-28 3M Innovative Properties Company Particules abrasives magnétisables et articles abrasifs les comprenant
CN112041118B (zh) 2018-03-29 2023-10-27 圣戈班磨料磨具有限公司 低脱落非织造磨料制品
WO2020212779A1 (fr) * 2019-04-16 2020-10-22 3M Innovative Properties Company Article abrasif et son procédé de fabrication

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AU2003302424A1 (en) 2004-06-18

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