Abstract: A method for making a nonwoven a abrasive article. A preferred aspect of the method comprises the steps of: a) providing a nonwoven web having a first side and a second side, the web comprising a plurality of fibers; b) frothing a liquid make coat precursor; c) applying the frothed make coat precursor to at least the first side of the web in such a manner so as to achieve a substantially uniform coating of the make coat precursor along the fibers of the web; d) spraying a plurality of fine abrasive particles onto the first side of the web, wherein the particles are sprayed so as to form a cloud of abrasive particles that deposit onto the fibers of the web in a substantially uniform distribution; and e) curing the make coat precursor to thereby form a hardened make coat which adheres the abrasive particles to the web and wherein the abrasive particles substantially protrude from the outer surface of the hardened make coat.

Abstract: Abrasive foam articles and a method of manufacture of such articles are described. The articles of the invention comprise a flexible and resilient foam substrate having first and second major substrate surfaces, at least one of the surfaces having a plurality of open cells substantially across the substrate surface, the open cells having coatable surfaces defined by interconnected voids; and a plurality of abrasive particles adhered to said coatable surfaces of said open cells in a substantially uniform manner.

Abstract: A method for making an abrasive article is described including the steps of providing an organic substrate; contacting the organic substrate with dry particulate solid material comprising a binder material, the binder material comprising a plurality of fusible organic particles, and a plurality of abrasive particles; inducing the fusible organic particles to liquefy; and solidifying the organic particles to thereby bond the particles to the organic substrate to provide an abrasive article. The invention provides a facile method for bonding abrasive particles to an organic substrate while reducing emissions at processing.

Abstract: Lofty, low density nonwoven pads and a process for the manufacture of such pads are described. The pads of the invention each comprise a bundle of discontinuous fibers bonded to one another at their mutual points of contact. The fibers are arranged within the bundle to provide a dense longitudinal central portion extending to opposite ends of the bundle, less dense side portions, a longitudinal tensile strength and a transverse tensile strength, wherein the longitudinal tensile strength is greater than the transverse tensile strength. The pads are made according to a process comprising forming a tow of discontinuous fibers so that the fibers are arranged within the tow to extend along a first axis, twisting the tow along the first axis to form a slubbed tow, bonding the fibers to one another at their mutual contact points and cutting the slubbed tow into scouring pads and the like.

Abstract: An open low-density abrasive article comprising in combination:(a) a lofty, open, nonwoven three-dimensional fibrous web formed of a plurality of interentangled randomly-extending polyamide staple fibers including points of intersection and contact between the fibers, the points of intersection and contact between the fibers being bonded together to form a three-dimensionally integrated structure throughout the web, wherein the fibers comprise surfaces and a fiber tenacity of less than 5 g/denier; (b) abrasive particles dispersed throughout the web and securely adhered to the surfaces of the fibers; and (c) resinous material dispersed throughout the web comprising (i) a hard phenolic resin formed as a cured product of a phenolic resin precursor distributed throughout the web and in contact with the fibers, and (ii) a modifier component of the type and in an amount effective to substantially prevent chemical degradation of the fibers while in contact with the phenolic resin precursor.