ABRASIVE BUFFING ARTICLES

Abstract

The present disclosure relates to abrasive buffing articles (“abrasive buffs”) and methods of making the same. The abrasive buffs include a substrate, such as a fabric, that has been impregnated with an abrasive polymeric composition that includes abrasive particles, such as primary abrasive particles and/or abrasive aggregates, such as spray dried abrasive aggregates. The abrasive buffs are flexible and capable of conforming to and effectively abrading, polishing, and buffing workpieces possessing a complex geometry.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/441,216 entitled “Abrasive Buffing Articles”, by Jianna Wang, Ying Cai, Mike D. Shappell, and Shu Yang, filed Dec. 31, 2016, which is assigned to the current assignee hereof and incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present inventive embodiments relate to abrasive buffing articles (“abrasive buffs”) and methods of making the same. The abrasive buffs include a substrate, such as a fabric, that has been impregnated with an abrasive polymeric composition that includes abrasive particles, such as spray dried abrasive aggregates. The abrasive buffs are flexible and capable of conforming to and effectively abrading, polishing, and buffing workpieces possessing a complex geometry.

BACKGROUND

Conventional buffs and buffing wheels (collectively referred to herein as “buffs”) are used to polish parts made of metal, plastic, ceramic, glass, wood, stone, silicon, an optical materials, among others. Buffing is a finishing process which is typically accomplished a more rigorous stock removal treatment of a surface.

Buffs are frequently categorized as either “cut” buffs or “color” buffs. A “cut” buff is more aggressive and is typically employed with a coarser buffing compound, a medium to high pressure between the buff and the work piece, and the work piece is advanced against the direction of rotation of the buff. This results in the refinement of scratches on the work piece and yields a uniform matte finish. In contrast, a “color” buff is typically employed with a finer buffing compound, a medium to low pressure between the buff and the work piece, and the work piece is advanced in the direction of rotation of the buff. Application of a color buff results in a further refinement of scratches in the surface of the work piece and yields a reflective, mirror-like finish.

Conventional buffs are typically free of any fixed abrasive material. Instead, abrasive emulsions or solid waxy abrasive compounds are externally applied to the working surface of the buff, and periodically reapplied, during abrasive operations. Conventional buffing systems have various draw backs including high costs of maintaining and cleaning the abrasive compound transport and application systems, high material waste during buffing processes, and costs and concerns associated with disposal of abrasive compounds.

Therefore, there continues to be a demand for improved abrasive products and methods that can offer enhanced abrasive processing performance, efficiency, and improved surface quality.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited in the accompanying figures.

FIG. 1 is an image of an abrasive buff according to an embodiment.

FIG. 2A is an image of an abrasive buff (“Airway buff”) according to an embodiment.

FIG. 2B is an image of an abrasive buff (“Pleated buff”) according to an embodiment.

FIG. 2C is an image of an abrasive buff (“Finger buff”) according to an embodiment.

FIG. 2D is an image of an abrasive buff (“Spiral sewn buff”) according to an embodiment.

FIG. 2E is an image of an abrasive buff (“String buff”) according to an embodiment.

FIG. 3 is a process flow diagram of a method of making an abrasive buff according to an embodiment.

FIG. 4 is an illustration of a woven fabric substrate being dip coated with an abrasive composition according to an embodiment.

FIG. 5A is an image of a woven fabric substrate according to an embodiment.

FIG. 5B is a magnified image of the same woven fabric shown in FIG. 5A.

FIG. 6A is an image of an abrasive composition (abrasive grains in a polymeric binder composition) disposed on a surface of a woven fabric substrate of an abrasive buff where the abrasive grains penetrate into and between the fibers of the woven fabric substrate according to an embodiment.

FIG. 6B is a cross sectional image of the same embodiment shown in FIG. 6A and shows that the abrasive composition is disposed on both surfaces (i.e., the front and the back) of the woven fabric substrate and the abrasive grains penetrating into and between the fibers of the woven fabric.

FIG. 7A is an image of an abrasive composition (abrasive grains in a polymeric binder composition) disposed on a surface of a woven fabric substrate of an abrasive buff where the abrasive grains penetrate into and between the fibers of the woven fabric substrate according to an embodiment.

FIG. 7B is a cross sectional image of the same embodiment shown in FIG. 7A and shows that the abrasive composition is disposed on both surfaces of the woven fabric substrate and the abrasive grains penetrating into and between the fibers of the woven fabric.

FIG. 8A is an image of an abrasive composition (abrasive grains in a polymeric binder composition) disposed on a surface of a woven fabric substrate of an abrasive buff where the abrasive grains penetrate into and between the fibers of the woven fabric substrate according to an embodiment.

FIG. 8B is a cross sectional image of the same embodiment shown in FIG. 8A and shows that the abrasive composition is disposed on both surfaces of the woven fabric substrate and the abrasive grains penetrating into and between the fibers of the woven fabric.

FIG. 9A is an image of an abrasive composition (abrasive grains in a polymeric binder composition) disposed on a surface of a woven fabric substrate of an abrasive buff where the abrasive grains penetrate into and between the fibers of the woven fabric substrate according to an embodiment.

FIG. 9B is a cross sectional image of the same embodiment shown in FIG. 9A and shows that the abrasive composition is disposed on both surfaces of the woven fabric substrate and the abrasive grains penetrating into and between the fibers of the woven fabric.

FIG. 10A is an image of an abrasive composition (abrasive grains in a polymeric binder composition) disposed on a surface of a woven fabric substrate of an abrasive buff where the abrasive grains penetrate into and between the fibers of the woven fabric substrate according to an embodiment.

FIG. 10B is a cross sectional image of the same embodiment shown in FIG. 10A and shows that the abrasive composition is disposed on both surfaces of the woven fabric substrate and the abrasive grains penetrating into and between the fibers of the woven fabric.

FIG. 11A is an image of an abrasive composition (abrasive grains in a polymeric binder composition) disposed on a surface of a woven fabric substrate of an abrasive buff where the abrasive grains penetrate into and between the fibers of the woven fabric substrate according to an embodiment.

FIG. 11B is a cross sectional image of the same embodiment shown in FIG. 11A and shows that the abrasive composition is disposed on both surfaces of the woven fabric substrate and the abrasive grains penetrating into and between the fibers of the woven fabric.

FIG. 12A is an image of an abrasive buff according to an embodiment.

FIG. 12B is an image of a side view of the abrasive buff of FIG. 12A showing multiple plies (6-ply) of the abrasive woven fabric according to an embodiment.

FIG. 13A is an image of an abrasive buff according to an embodiment.

FIG. 13B is an image of a side view of the abrasive buff of FIG. 13A showing multiple plies (12-ply) of the abrasive woven fabric according to an embodiment.

FIG. 13C is an image of a somaparative abrasive buff and fixed abrasive buffs according to embodiments.

FIG. 14 is an image showing an abrasive buff according to an embodiment set up to conduct abrasive testing of the woven abrasive article.

FIG. 15 is an illustration of the set up to conduct 5 Degree Angle testing on a work piece.

FIG. 16A is a graph comparing gloss (20°) performance of a conventional manual buffing process (conventional buffing article and conventional bar/stick abrasive) to an automated buffing process using an inventive buffing article according to an embodiment.

FIG. 16B is a graph comparing surface finish (Ra) performance of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 16C is a graph comparing power (hp) consumption of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 16D is a graph comparing surface finish (Rz) performance of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 17A is a graph comparing gloss (20°) performance of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 17B is a graph comparing surface finish (Ra) performance of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 17C is a graph comparing power (hp) consumption of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 17D is a graph comparing surface finish (Rz) performance of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 18A is a graph comparing gloss (20°) performance of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 18B is a graph comparing surface finish (Ra) performance of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

FIG. 18C is a graph comparing power (hp) consumption of a conventional manual buffing process (conventional buff and conventional bar/stick abrasive) to an automated buffing process using an inventive buff according to an embodiment.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.

DETAILED DESCRIPTION

The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other embodiments can be used based on the teachings as disclosed in this application.

The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a 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 method, article, or apparatus. Further, unless expressly stated to the contrary, “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).

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one, or the singular as also including the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

As used herein, the term “aggregate” may be used to refer to a particle made of a plurality of smaller particles that have been combined in such a manner that it is relatively difficult to separate or disintegrate the aggregate particle into smaller particles by the application of pressure or agitation. This is in contrast to the term “agglomerate,” which is used herein to refer to a particle made up of a plurality of smaller particles that have been combined in such a manner that it is relatively easy to separate the agglomerate particle or disintegrate the agglomerate particle back into smaller particles, such as by the application of pressure or hand agitation.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and may be found in textbooks and other sources within the abrasive arts.

FIG. 1 shows an image of an embodiment of an abrasive buffing article (100) (“abrasive buff”) comprising: a plurality of woven fabric layers (102). An abrasive composition is fixed to each of the fabric layers. Each of the fabric layers comprises a plurality of yarns, wherein the abrasive composition is disposed at least partially within the yarns and/or between the yarns. The abrasive composition comprises a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder.

FIG. 3 shows a process flow diagram of a method 300 of forming an abrasive buff. Step 302 comprises mixing together a plurality of abrasive grains and a polymeric binder to form a precursor composition. In an embodiment, the abrasive grains can comprise abrasive aggregates. Step 304 comprises impregnating a woven fabric with the precursor composition. In an embodiment, the abrasive grains penetrate into and between the fibers of the woven fabric. In an embodiment, the precursor composition can be disposed on both surfaces (i.e., the front side and the back side) of the woven fabric. Step 306 comprises curing the precursor composition to form an abrasive woven cloth. Step 308 comprises forming the abrasive woven cloth into an abrasive buff.

FIG. 6A is an image of a surface of a woven fabric substrate of an abrasive buff where an abrasive composition (i.e., abrasive grains dispersed in a polymeric binder composition) is disposed on and in the fabric such that the abrasive composition (including the abrasive grains) penetrate into and between the fibers of the woven fabric substrate according to an embodiment.

FIG. 6B is a cross sectional image of the same embodiment shown in FIG. 6A and shows that the abrasive composition is disposed on both surfaces (i.e., the front side and the back side) of the woven fabric substrate. The abrasive composition (including the abrasive grains) is penetrating into and between the fibers of the woven fabric.

Abrasive Fabric Composition

The abrasive fabric of the abrasive buff can comprise varying amounts of abrasive composition. In an embodiment, the amount of abrasive composition can comprise as least 30 wt % of the abrasive fabric, such as at least 35% wt %, at least 38 wt %, at least 40 wt %, at least 42 wt %, or at least 44 wt % of the abrasive fabric. In another embodiment, the abrasive composition can comprise not greater than 85 wt % of the abrasive fabric, such as not greater than 80 wt %, not greater than 75 wt %, not greater than 70 wt %, not greater than 65 wt %, not greater than 60 wt %, or not greater than 55 wt % of the abrasive fabric. The amount of the abrasive composition can be within a range of any minimum or maximum value noted above. In a specific embodiment, the amount of the abrasive composition can comprise from at least 30 wt % to not greater than 85 wt % of the abrasive fabric, such as at least 35 wt % to not greater than 80 wt % of the abrasive fabric, such as at least 40 wt % to not greater than 75 wt % of the abrasive fabric, such as at least 40 wt % to not greater than 70 wt % of the abrasive fabric.

The abrasive fabric of the abrasive buff can comprise varying amounts of fabric. In an embodiment, the amount of fabric can comprise as least 10 wt % of the abrasive fabric, such as at least 15% wt %, at least 20 wt %, at least 25 wt %, at least 30 wt %, or at least 35 wt % of the abrasive fabric. In another embodiment, the fabric can comprise not greater than 70 wt % of the abrasive fabric, such as not greater than 65 wt %, not greater than 60 wt %, not greater than 55 wt %, or not greater than 50 wt % of the abrasive fabric. The amount of the fabric can be within a range of any minimum or maximum value noted above. In a specific embodiment, the amount of the fabric can comprise from at least 15 wt % to not greater than 70 wt % of the abrasive fabric, such as at least 20 wt % to not greater than 65 wt % of the abrasive fabric.

Fabric Layer

An abrasive buff can comprise a plurality of fabric layers. In an embodiment, each of the fabric layers can comprise an abrasive composition fixed to each of the fabric layers. In an embodiment, the fabric layers can comprise woven fabric layers. In an embodiment, the abrasive composition can be disposed on a first side of the woven fabric. In an embodiment, the abrasive composition is further disposed on a second side of the fabric. In an embodiment, the woven fabric can comprise a plurality of yarns, such as warp yarns and weft yarns. In an embodiment, the abrasive composition can be disposed at least partially within or between the yarns, such as between the warp and weft yarns. In an embodiment, the abrasive composition can be further disposed through the fabric between the yarns from the first side of the fabric to the second side of the fabric.

Number of Fabric Layers

An abrasive buff can comprise a plurality of fabric layers (also called “plys”). In an embodiment, the number of fabric layers can be at least 2 layers, such as at least 4 layers, at least 6 layers, at least 8 layers, or at least 10 layers. In another embodiment, the number of layers can be not greater than 20 layers, such as not greater than 18 layers, not greater than 16 layers, not greater than 14 layers, or not greater than 12 layers. The number of fabric layers can be within a range of any minimum or maximum value noted above. In a specific embodiment, the number of fabric layers can comprise from at least 2 layers to not greater than 20 layers, such as from at least 4 layers to not greater than 18 layers, at least 6 layers to not greater than 16 layers, or at least 8 layers to not greater than 14 layers.

Weave

The fabric layer can comprise a woven cloth. In an embodiment, the woven cloth can comprise one or a plurality of woven patterns, including a plain weave, a basket weave, a rib weave, a balanced plain weave, a twill weave, a satin weave, or a combination thereof.

Thread Count—Warp

The thread count of a woven cloth can vary in the warp direction and vary in the weft direction. In an embodiment, the woven cloth can comprise at least 50 threads per inch in the warp direction, such as least 55 threads per inch, at least 60 threads per inch, at least 65 threads per inch, at least 70 per inch, at least 75 threads per inch, at least 80 threads per inch, at least 85 threads per inch, or at least 90 threads per inch. In another embodiment, the woven cloth can comprise not greater than 300 threads per inch, such as not greater than 280 threads per inch, not greater than 260 threads per inch, not greater than 240 threads per inch, not greater than 220 threads per inch, or not greater than 200 threads per inch. The threads per inch can be within a range of any minimum or maximum value noted above. In a specific embodiment, the amount of threads per inch can comprise from at least 50 threads per inch to not greater than 300 threads per inch in the warp direction, such as from 50 threads per inch to not greater than 100 threads per inch, or from 100 threads per inch to not greater than 300 threads per inch.

Thread Count—Weft

The thread count of a woven cloth can vary in the weft direction and vary in the weft direction. In an embodiment, the woven cloth can comprise at least 50 threads per inch in the weft direction, such as least 55 threads per inch, at least 60 threads per inch, at least 65 threads per inch, at least 70 per inch, at least 75 threads per inch, at least 80 threads per inch, at least 85 threads per inch, or at least 90 threads per inch. In another embodiment, the woven cloth can comprise not greater than 300 threads per inch, such as not greater than 280 threads per inch, not greater than 260 threads per inch, not greater than 240 threads per inch, not greater than 220 threads per inch, or not greater than 200 threads per inch. The threads per inch can be within a range of any minimum or maximum value noted above. In a specific embodiment, the amount of threads per inch can comprise from at least 50 threads per inch to not greater than 300 threads per inch in the weft direction, such as from 50 threads per inch to not greater than 100 threads per inch, or from 100 threads per inch to not greater than 300 threads per inch.

Ratio—Warp:Weft

The ratio of warp threads to weft threads of a woven fabric layer can vary. In an embodiment, the woven cloth comprises a ratio of warp threads to weft threads (warp:weft) ranging from 1:6 (e.g., 50/300 thread count) to 6:1 (e.g., 300/50 thread count), such as from 1:2 to 2:1, or from 1:1.8 to 1:1.

Fabric Weight

The “weight” (mass per area) of a fabric can vary. In an embodiment, the fabric weight can comprise at least 50 GSM, such as least 75 GSM, at least 100 GSM, or at least 150 GSM GSM. In another embodiment, the fabric weight can comprise not greater than 800 GSM, such as not greater than 700 GSM, not greater than 600 GSM, not greater than 500 GSM, not greater than 400 GSM, not greater than 300 GSM, not greater than 275 GSM, not greater than 250 GSM, not greater than 225 GSM, or not greater than 200 GSM. The fabric weight can be within a range of any minimum or maximum value noted above. In a specific embodiment, the fabric weight can comprise a weight of at least 50 grams per square meter (“GSM”) to not greater than 800 GSM, such as at least 100 GSM to not greater than 500 GSM.

Fabric Type

The fabric can comprise natural fibers, synthetic fibers, or a combination thereof. Natural fibers can comprise one or more natural fibers. In an embodiment, natural fibers can comprise cellulose, cotton, flax, hemp, jute, ramie, sisal, linen, silk, or a combination thereof. In another embodiment, natural fibers can comprise cotton. In a specific embodiment, natural fibers can consist essentially of cotton. Synthetic fibers can comprise one or more synthetic fibers. In an embodiment, synthetic fibers can comprise a polymer, a glass, a metal, a rubber, carbon, or a combination thereof. In another embodiment, synthetic fibers can comprise a polymer fiber. In a specific embodiment, a polymer fiber can comprise nylon, acrylic, olefin, polyester, rayon, modal, Dyneema, or a combination thereof. In a particular embodiment, a polymer fiber comprises polyester. In a specific embodiment, a synthetic fiber can consist essentially of polyester.

Abrasive Composition (Cured Composition)

The abrasive buff comprises an abrasive composition fixed to each of the fabric layers. The abrasive composition can comprise a plurality of abrasive particles (also called abrasive grains herein) disposed on or in a polymeric binder. In an embodiment, the abrasive composition can further comprise a rheology modifier.

The amount of abrasive particles comprising the abrasive composition can vary. In an embodiment, the abrasive composition can comprise at least 20 wt % abrasive particles, such as 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. In another embodiment, the abrasive composition can comprise not greater than 90 wt % abrasive particles, such as not greater than 85 wt %, not greater than 80 wt %, or not greater than 75 wt % abrasive particles. The abrasive particles can be within a range of any minimum or maximum value noted above. In a specific embodiment, the amount of abrasive particles in the abrasive composition can comprise from at least 20 wt % to not greater than 90 wt %, such as from at least 40 wt % to not greater than 85 wt %, or from 60 wt % abrasive particles to not greater than 80 wt % abrasive particles.

The amount of polymeric binder comprising the abrasive composition can vary. In an embodiment, the abrasive composition can comprise at least 10 wt % polymeric binder, such as least 15 wt %, at least 20 wt %, or at least 25 wt % polymeric binder. In another embodiment, the abrasive composition can comprise not greater than 80 wt % polymeric binder, such as 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 %, not greater than 50 wt %, not greater than 40 wt %, not greater than 35 wt %, or not greater than 30 wt % polymeric binder. The polymeric binder can be within a range of any minimum or maximum value noted above. In a specific embodiment, the amount of polymeric binder in the abrasive composition can comprise from at least 10 wt % to not greater than 80 wt %, such as from at least 15 wt % to not greater than 70 wt %, or from 20 wt % polymeric binder to not greater than 60 wt % polymeric binder.

The amount of rheology modifier (also called a thickener herein) comprising the abrasive composition can vary. In an embodiment, the abrasive composition can comprise at least 0.3 wt % rheology modifier, such as least 0.4 wt %, at least 0.5 wt %, or at least 0.6 wt % rheology modifier. In another embodiment, the abrasive composition can comprise not greater than 10 wt % rheology modifier, such as not greater than 8 wt %, not greater than 6 wt %, not greater than 4 wt %, or not greater than 2 wt %. The rheology modifier can be within a range of any minimum or maximum value noted above. In a specific embodiment, the amount of rheology modifier in the abrasive composition can comprise from at least 0.3 wt % to not greater than 10 wt %, such as from at least 0.4 wt % to not greater than 6 wt %.

Abrasive Particles

Abrasive particles can include essentially single phase inorganic materials, such as alumina, silicon carbide, silica, ceria, and harder, high performance superabrasive particles such as cubic boron nitride and diamond. Additionally, the abrasive particles can include composite particulate materials. Such materials can include aggregates, 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. Further, the abrasive regions can include engineered abrasives including macrostructures and particular three-dimensional structures. In certain embodiments, the abrasive particles comprise primary particles, aggregates, or a combination thereof. In certain embodiments, when the abrasive particles are at least partially abrasive aggregates, the abrasive aggregates may comprise unfired abrasive aggregates having a generally spheroidal or toroidal shape that are formed from a composition of abrasive grit particles and a nanoparticle binder (Nanozyte aggregates). In certain embodiments, the aggregates may be hollow and may comprise an interior space (Nanozyte aggregates).

In an embodiment, the abrasive particles are blended with a polymeric binder to form abrasive slurry. Alternatively, the abrasive particles are applied over the polymeric binder after the polymeric binder is coated on the backing. Optionally, a functional powder can be applied over the abrasive regions to prevent the abrasive regions from sticking to a patterning tooling. Alternatively, patterns can be formed in the abrasive regions absent the functional powder.

The abrasive particles can be formed of any one of or a combination of abrasive particles, including silica, alumina (fused or sintered), zirconia, zirconia/alumina oxides, 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, and Tripoli. For example, the abrasive particles can 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. Particular embodiments have been created by use of dense abrasive particles comprised principally of alpha-alumina.

The abrasive grain can also have a particular shape. An example of such a shape includes a rod, a triangle, a pyramid, a cone, a solid sphere, a hollow sphere, or the like. Alternatively, the abrasive grain can be randomly shaped.

In certain embodiments, a portion of the abrasive particles of the aggregate component may include a coating of a polymer component disposed between the abrasive particle and the polymeric binder. In certain embodiments, the polymer component may be directly in contact with the abrasive particles.

Particle Size

In an embodiment, the abrasive particles can have an average particle size not greater than 4000 microns, such as not greater than 2000 microns, such as not greater than about 1500 microns, not greater than about 1000 microns, not greater than about 750 microns, not greater than about 500 microns, not greater than about 250 microns, not greater than about 100 microns, or not greater than 50 microns. In another embodiment, the abrasive particle size can be at least 0.1 microns, such as at least 1 micron, at least 5 microns, at least 6 microns, at least 7 microns, at least 8 microns, at least 9 microns, at least 10 microns, at least 15 microns, at least 20 microns, or at least 25 microns. The average particle size can be within a range of any minimum or maximum value noted above. In a specific embodiment, the average particle size can comprise from at least 1 micron to not greater than 2000 microns, such as from at least 5 microns to not greater than 1000 microns, at least 5 microns to not greater than 750 microns, at least 6 microns to not greater than 500 microns, at least 7 microns to not greater than 250 microns, or at least 8 microns to not greater than 100 microns. 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. In some instances, the particle size distribution is tightly controlled.

Polymeric Binder

The polymeric binder can be formed of a single polymer or a blend of polymers. The binder composition can be formed from an epoxy composition, acrylic composition, a phenolic composition, a polyurethane composition, a phenolic composition, a polysiloxane composition, an acrylic latex, or combinations thereof. In addition, the binder composition can include active filler particles, as described above, additives, or a combination thereof. In certain embodiments, the polymeric binder can be flexible.

The polymeric binder generally includes a polymer matrix, which binds abrasive particles to the backing or to a compliant coat, if such a compliant coat is present. Typically, the polymeric binder is formed of cured polymeric binder. In an embodiment, the polymeric binder includes a polymer component and a dispersed phase.

The polymeric binder can include one or more reaction constituents or polymer constituents for the preparation of a polymer. A polymer constituent can include a monomeric molecule, a polymeric molecule, or a combination thereof. The polymeric binder can further comprise components selected from the group consisting of solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators and agents for influencing the fluidity of the dispersion.

The polymer constituents can form thermoplastics or thermosets. By way of example, the polymer constituents can include monomers and resins for the formation of polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), polymerized alkyd, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, or, in general, reactive resins for the production of thermoset polymers. Another example includes an acrylate or a methacrylate polymer constituent. The precursor polymer constituents are typically curable organic material (i.e., a polymer monomer or material capable of polymerizing or crosslinking upon exposure to heat or other sources of energy, such as electron beam, ultraviolet light, visible light, etc., or with time upon the addition of a chemical catalyst, moisture, or other agent which cause the polymer to cure or polymerize). A precursor polymer constituent example includes a reactive constituent for the formation of an amino polymer or an aminoplast polymer, such as alkylated urea-formaldehyde polymer, melamine-formaldehyde polymer, and alkylated benzoguanamine-formaldehyde polymer; acrylate polymer including acrylate and methacrylate polymer, alkyl acrylate, acrylated epoxy, acrylated urethane, acrylated polyester, acrylated polyether, vinyl ether, acrylated oil, or acrylated silicone; alkyd polymer such as urethane alkyd polymer; polyester polymer; reactive urethane polymer; phenolic polymer such as resole and novolac polymer; phenolic/latex polymer; epoxy polymer such as bisphenol epoxy polymer; isocyanate; isocyanurate; polysiloxane polymer including alkylalkoxysilane polymer; or reactive vinyl polymer. The polymeric binder can include a monomer, an oligomer, a polymer, or a combination thereof. In a particular embodiment, the polymeric binder includes monomers of at least two types of polymers that when cured can crosslink. For example, the binder formulation can include epoxy constituents and acrylic constituents that when cured form an epoxy/acrylic polymer. In a specific embodiment, the polymeric binder can comprise at least one of a polyurethane, a phenolic, an acrylic latex, or a combination thereof.

The polymeric binder can comprise a desirable glass transition temperature (Tg) that can contribute to beneficial abrasive properties. In an embodiment, the polymeric binder can comprise a glass transition temperature (Tg) 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. In another embodiment, the polymeric binder can comprise a glass transition temperature (Tg) of at least −30° C., at least −25° C., at least −20° C., or at least −15° C. The glass transition temperature (Tg) can be within a range of any minimum or maximum value noted above. In a specific embodiment, the glass transition temperature (Tg) can comprise from at least −30° C. to not greater than 30° C., such as from at least −20° C. to not greater than 20° C.

Rheology Modifier

In an embodiment, the abrasive composition can comprise a rheology modifier. The rheology modifier can comprise a cellulose compound, a fumed silica, or a combination thereof. In a specific embodiment, the cellulose compound can comprise a hydroxypropyl cellulose.

EMBODIMENTS LISTING

Embodiment 1

An abrasive buff comprising:

a plurality of woven fabric layers; and

an abrasive composition fixed to each of the fabric layers,

wherein each of the fabric layers comprises a plurality of yarns,

wherein the abrasive composition is disposed at least partially within the yarns, and

wherein the abrasive composition comprises a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder.

Embodiment 2

The abrasive buff of embodiment 1, wherein the abrasive composition comprises:

15 wt % to 90 wt % of the abrasive buff.

Embodiment 3

The abrasive buff of embodiment 1, wherein fabric layers comprise: 10 wt % to 85 wt % of the abrasive buff.

Embodiment 4

The abrasive buff of embodiment 1, wherein the fabric layer comprises a woven cloth.

Embodiment 5

The abrasive buff of embodiment 4, wherein woven cloth comprises a thread count in a range from 50 to 300 threads per inch in the warp direction.

Embodiment 6

The abrasive buff of embodiment 4, wherein woven cloth comprises a thread count in a range from 50 to 300 threads per inch in the weft direction.

Embodiment 7

The abrasive buff of embodiment 4, wherein woven cloth comprises a thread count of 50/50 to 300/300.

Embodiment 8

The abrasive buff of embodiment 4, wherein woven cloth comprises a ratio of warp thread count to weft thread count ranging from 1:1.8 to 1:1.

Embodiment 9

The abrasive buff of embodiment 4, wherein the woven cloth comprises fibers having a linear density in a range of 0.1 denier to 500 denier.

Embodiment 10

The abrasive buff of embodiment 1, wherein the fabric comprises a weight of grams per square meter (“GSM”) in a range of 100 to 800 GSM.

Embodiment 11

The abrasive buff of embodiment 1, wherein the fabric comprises synthetic fibers, natural fibers, or a combination thereof.

Embodiment 12

The abrasive buff of embodiment 11, wherein the natural fibers comprise cotton.

Embodiment 13

The abrasive buff of embodiment 1, wherein the fabric layer is coated with the abrasive composition on a first side.

Embodiment 14

The abrasive buff of embodiment 1, wherein the fabric layer is further coated with the abrasive composition on a second side.

Embodiment 15

The abrasive buff of embodiment 1, wherein the abrasive composition comprises 20 wt % to 90 wt % of abrasive grains.

Embodiment 16

The abrasive buff of embodiment 1, wherein the abrasive composition comprises 10 wt % to 80 wt % of a polymeric binder composition.

Embodiment 17

The abrasive buff of embodiment 1, wherein the abrasive composition further comprises a rheology modifier.

Embodiment 18

The abrasive buff of embodiment 17, wherein the abrasive composition comprises 0.1 wt % to 10 wt % of the rheology modifier.

Embodiment 19

The abrasive buff of embodiment 17, wherein the rheology modifier comprises a cellulose compound, a fumed silica, or a combination thereof.

Embodiment 20

The abrasive buff of embodiment 1, wherein the abrasive composition is disposed on a first side of the woven fabric.

Embodiment 21

The abrasive buff of embodiment 20, wherein the abrasive composition is further disposed on a second side of the fabric.

Embodiment 22

The abrasive buff of embodiment 21, wherein the abrasive composition is further disposed through the fabric between the yarns from the first side of the fabric to the second side of the fabric.

Embodiment 23

The abrasive buff of embodiment 22, wherein the abrasive composition is further disposed between the fibers of the fabric layer.

Embodiment 24

The abrasive buff of embodiment 1, wherein the abrasive particles comprise primary abrasive particles, abrasive aggregates, or a combination thereof.

Embodiment 25

The abrasive buff of embodiment 24, wherein the abrasive particles comprise primary abrasive particles.

Embodiment 26

The abrasive buff of embodiment 24, wherein the abrasive particles comprise abrasive aggregates.

Embodiment 27

The abrasive buff of embodiment 26, wherein the abrasive aggregates comprise unfired abrasive aggregates having a generally spheroidal or toroidal shape that are formed from a composition of abrasive grit particles and a nanoparticle binder.

Embodiment 28

The abrasive buff of embodiment 27, wherein the aggregates are hollow and comprise an interior space.

Embodiment 29

The abrasive buff of embodiment 1, wherein the abrasive particles comprise silica, silicon carbide, Tripoli, aluminum oxide, or a combination thereof.

Embodiment 30

The abrasive buff of embodiment 1, wherein the polymeric binder is flexible.

Embodiment 31

The abrasive buff of embodiment 1, wherein the polymeric binder has a glass transition temperature (Tg) of not greater than 10° C.

Embodiment 32

The abrasive buff of embodiment 1, wherein polymeric binder has a glass transition temperature (Tg) in a range of −30° C. to 60° C.

Embodiment 33

The abrasive buff of embodiment 1, wherein the polymeric binder comprises a polyurethane composition, a phenolic composition, an acrylic latex composition, or a combination thereof.

Embodiment 34

An abrasive buff comprising: a plurality of fabric layers; and an abrasive composition fixed to each of the fabric layers, wherein the abrasive composition is disposed at least partially within each of the fabric layers, wherein the abrasive composition comprises a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder, and wherein the polymeric binder the polymeric binder has a glass transition temperature (Tg) of not greater than 10° C.

Embodiment 35

A method of forming a buff wheel comprising:

providing a fabric substrate; providing an abrasive composition, the abrasive composition comprising:

• • a plurality of abrasive aggregates; and
  • a polymeric binder; at least partially impregnating the fabric substrate with the abrasive composition; and configuring the fabric substrate into a buff wheel.

Embodiment 36

A method of forming an abrasive buff comprising:

mixing together a plurality of abrasive grains and a polymeric binder to form a precursor composition;

impregnating a woven fabric with the precursor composition;

curing the precursor composition to form an abrasive woven cloth;

forming the abrasive woven cloth into an abrasive buff.

Embodiment 37

The method of forming an abrasive buff of embodiment 36, wherein the abrasive grains are abrasive aggregates.

Embodiment 38

The method of forming an abrasive buff of embodiment 35, wherein the polymeric composition comprises a glass transition temperature (Tg) of not greater than 10° C.

Embodiment 39

An abrasive buff comprising:

a plurality of woven fabric layers; and

an abrasive composition fixed to each of the fabric layers,

wherein each of the fabric layers comprises a plurality of yarns,

wherein the abrasive composition is disposed at least partially within the yarns, and

wherein the abrasive composition comprises:

• • a polymeric binder and
  • a plurality of abrasive particles dispersed in the polymeric binder.

Embodiment 40

The abrasive buff of embodiment 39, wherein the abrasive composition comprises:

15 wt % to 90 wt % of the abrasive buff.

Embodiment 41

The abrasive buff of embodiment 39, wherein fabric layers comprise: 10 wt % to 85 wt % of the abrasive buff.

Embodiment 42

The abrasive buff of embodiment 39, wherein the woven fabric layer comprises a woven cloth.

Embodiment 43

The abrasive buff of embodiment 42, wherein the woven cloth comprises a thread count in a range from 50 to 300 threads per inch in the warp direction.

Embodiment 44

The abrasive buff of embodiment 42, wherein the woven cloth comprises a thread count in a range from 50 to 300 threads per inch in the weft direction.

Embodiment 45

The abrasive buff of embodiment 42, wherein woven cloth comprises a ratio of warp thread count to weft thread count ranging from 1:1.8 to 1:1.

Embodiment 46

The abrasive buff of embodiment 42, wherein the woven cloth comprises fibers having a linear density in a range of 0.1 denier to 500 denier.

Embodiment 47

The abrasive buff of embodiment 39, wherein the fabric comprises a weight of grams per square meter (“GSM”) in a range of 100 to 800 GSM.

Embodiment 48

The abrasive buff of embodiment 39, wherein the fabric comprises synthetic fibers, natural fibers, or a combination thereof.

Embodiment 49

The abrasive buff of embodiment 39, wherein the woven fabric layer is coated with the abrasive composition on a first side.

Embodiment 50

The abrasive buff of embodiment 49, wherein the woven fabric layer is further coated with the abrasive composition on a second side.

Embodiment 51

The abrasive buff of embodiment 39, wherein the abrasive composition comprises:

20 wt % to 90 wt % of abrasive grains and

10 wt % to 80 wt % of a polymeric binder composition.

Embodiment 52

The abrasive buff of embodiment 51, wherein the abrasive composition further comprises: 0.1 wt % to 10 wt % of a rheology modifier.

Embodiment 53

The abrasive buff of embodiment 52 wherein the rheology modifier comprises a cellulose compound, a fumed silica, or a combination thereof.

Embodiment 54

The abrasive buff of embodiment 50, wherein the abrasive composition is disposed through the fabric between the yarns from the first side of the fabric to the second side of the fabric.

Embodiment 55

The abrasive buff of embodiment 50, wherein the abrasive composition is disposed between the fibers of the woven fabric layer.

Embodiment 56

The abrasive buff of embodiment 39, wherein the polymeric binder is flexible.

Embodiment 57

The abrasive buff of embodiment 39, wherein the polymeric binder has a glass transition temperature (Tg) of not greater than 10° C.

Embodiment 58

An abrasive buff comprising:

a plurality of fabric layers; and

an abrasive composition fixed to each of the fabric layers,

wherein the abrasive composition is disposed at least partially within each of the fabric layers,

wherein the abrasive composition comprises a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder, and

wherein the polymeric binder the polymeric binder has a glass transition temperature (Tg) of not greater than 10° C.

EXAMPLES

The properties and advantage of the present disclosure are illustrated in further detail in the following nonlimiting examples. Unless otherwise indicated, temperatures are expressed in degrees Celsius, pressure is ambient, and concentrations are expressed in weight percentages.

Components Listing:

Green silicon carbide JIS graded: J700, J800, J1000, J1200 from Graystar LLC.

Hycar® 26345—acrylic emulsion from Lubrizol Advanced Materials, Inc.

Klucel™—M-hydroxypropyl cellulose thickener from Ashland.

Aerodisp® WR8520—fumed silica dispersion thickener from Evonik Industries.

Surfynol® DF70 Defoamer from Air Product.

Triton 102X Wetting agent from Dow Chemical.

Greige Cloth from Garfield Buff Company. The cloth has thread count of 90/76, cloth weight is 12.3 lbs./ream.

Double Ground Tripoli Rose

Nanozyte unfired aggregates of white aluminum oxide J1000 grit

White aluminum oxide J1200

Example 1—Preparation of Abrasive Compositions (Samples S1-S8)

Sample abrasive compositions S1-S4 having different types and amounts of abrasive particles and polymeric binder were prepared using the formulations listed in Table 1. Additional sample abrasive compositions S5-S8 having different types and amounts of abrasive particles and polymeric binder were prepared using the formulations listed in Table 2. The components were thoroughly mixed together and the resulting compositions were stored for later use.

TABLE 1
Abrasive Composition Formulation S1-S4
	S1	S1	S2	S2	S3	S3	S4	S4
	% Wet	% Dry	% Wet	% Dry	% Wet	% Dry	% Wet	% Dry
Hycar 26345	24.6	24.5	24.6	24.5	24.6	24.5	24.6	24.5
Green SiC	37.2	73.9	—	—	—	—	—	—
J1200
Green SiC	—	—	37.2	73.9	—	—	—	—
J1000
Green SiC	—	—	—	—	37.2	73.9	—	—
J800
Green SiC	—	—	—	—	—	—	37.2	73.9
J700
Water	24.1	—	24.2	—	24.1	—	24.6	—
6% Klucel	13.7	1.6	13.7	1.6	13.7	1.6	13.7	1.6
Wet Agent	.2	—	.2	—	.2	—	.2	—
Triton 102X
DF70	.2	—	.2	—	.2	—	.2	—
Total	100	100	100	100	100	100	100	100

TABLE 2
Abrasive Composition Formulation S5-S8
	S5	S5	S6	S6	S7	S7	S8	S8
	% Wet	% Dry	% Wet	% Dry	% Wet	% Dry	% Wet	% Dry
Hycar 26345	24.9	24.7	24.9	24.7	24.8	24.6	24.9	24.7
Green SiC	37.7	74.6	—	—	—	—	—	—
J1200
Double Ground	—	—	37.7	74.6	—	—	—	—
Tripoli Rose
Nanozyte	—	—	—	—	37.6	74.4	—	—
WA1000
WA J1200,	—	—	—	—	—	—	37.7	74.6
9.5mu
Water	30.9	—	30.9	—	29.3	—	35.1	—
6% Klucel	6.5	0.7	6.5	0.7	8.3	1.0	—	—
17% Klucel	—	—	—	—	—	—	2.3	0.7
Total	100	100	100	100	100	100	100	100

Example 2—Preparation of Abrasive Cloth (Samples S1-S8)

The sample abrasive compositions S1-S8 were used to prepare abrasive cloth. An uncoated “blank” 100% cotton Greige cloth (thread count 90/76, cloth weight 182 GSM) was unwound from a roll and dipped in the sample abrasive compositions using a dip tank. A portion of the uncoated Greige cloth was used as a control (C1). FIGS. 5A and 5B show the uncoated cloth C1. The dipped cloth was run through metering rolls to remove excess liquid. FIG. 4 shows an embodiment of the dipping step. The impregnated fabric was passed through an oven to cure the abrasive composition. The cured abrasive cloth was collected on a winding station for further processing. Abrasive sample cloths S1-S4 were produced as described. A second uncoated “blank” 100% cotton Greige cloth served as a second control (C2) and was used to produce sample abrasive cloth samples S5-S8. A portion of the sample abrasive cloths were cut into 3-inch OD circles (“discs”) for fabric analysis. The results of the testing are shown in Table 3. It was noted that all the completed samples S1-S8 were “soft” to the touch and retained their flexibility, “hand,” and “drape.”

TABLE 3
Sample Abrasive Cloth (S1-S4)
		Cured Add-On
		Abrasive
		Composition		Abrasive
Sample Disc	Total	Weight	Cloth	Composition
3″ OD round	Weight (g)	(g)	(wt %)	(wt %)
Control 1	0.8	0.0	100%	0%
(Blank Cloth)
S1	1.6	0.8	52%	48%
S2	1.4	0.6	59%	41%
S3	1.4	0.6	59%	41%
S4	1.5	0.7	55%	45%
Control 2	0.7	0.0	100%	0%
(Blank Cloth)
S5	1.5	0.8	46%	54%
S6	1.5	0.8	47%	53%
S7	1.7	1.0	42%	58%
S8	1.5	0.8	48%	52%

FIGS. 5A and 5B show images of uncoated control C1. FIGS. 6A and 6B show images of abrasive cloth sample S5. FIGS. 7A and 7B show images of abrasive cloth sample S6. FIGS. 8A and 8B show images of abrasive cloth sample S1. FIGS. 9A and 9B show images of abrasive cloth sample S2. FIGS. 10A and 10B show images of abrasive cloth sample S3. FIGS. 11A and 11B show images of abrasive cloth sample S4.

Example 3—Preparation of Abrasive Buffs (Samples S5-S8)

Buff wheels were created according to conventional methods (Garfield Buff Company, Fairfield, N.J.). The sample abrasive cloths were tucked into a metal clinch ring and a metal plate with center (“arbor”) hole was inserted. The buff wheel specifications were: 8 plys, 8″ OD, 3″ ID, arbor hole 1.5″. An exemplary sample buff wheel is shown in FIG. 1. FIGS. 12A and 12 B show sample pleated buffs. FIG. 13A and FIG. 13B show sample airway buffs. FIG. 13C shows sample airway buffs (wheel specifications: 8 plys, 8″ OD, 3″ ID, arbor hole 1.5″) comprising sample abrasive fabrics S5-S7 and control C2.

Example 4. Abrasive Testing of Buffs

Abrasive testing of sample fixed abrasive buffs S5-S8 was conducted on an automated Elb surface grinder. The goal was to investigate the polishing and wear behavior of the fixed abrasive buffs in an automated process compared to traditional bar compound buffing by hand. FIG. 14 displays the automated test setup.

Test workpieces were blocks of 304SS measuring 8″×4″×1″. Testing was directed to surface finish refinement and surface gloss improvement of rough workpiece. The initial surface of the workpieces were pre-ground with either a grinding wheel (surface “A”) or a grinding belt (surface “B”) to an initial surface roughness Ra of 15-20 μinches. It is generally believed that a grinding wheel tends to leave deeper surface features in a surface than a belt and both methods were used to better simulate a variety of field conditions.

For comparison, one 304SS part from the field was used for comparison with the automated buffing results. The comparative part was then manually buffed with a conventional Tripoli bar compound. The surface finish and surface gloss of both sides of the workpiece were measured. Buffing was conducted at a 5° angle from the grinding marks as shown in FIG. 15.

Sample inventive fixed abrasive buffs were tested against the conventional method of buffing (i.e., buffing with an uncoated buff and periodically applying traditional Tripoli bar compound to the buff surface during buffing).

FIGS. 16A, 16B, 16C, and 16D show surface gloss (20°), surface finish (Ra), power draw (hp), and surface finish (Rz) for inventive sample buffs S5 compared to control buff C2 on surface “A” workpieces. Sample buff S5 was first tested under dry conditions at 7500 SFPM for about a minute (S5 Dry A) and then water was sprayed onto the buff to cool the buffing process. Buffing was continued at 7500 SFPM (S5 Wet A). Additionally, another sample S5 buff was tested on a surface “B” workpiece under water spray conditions (S5 Wet B). Unexpectedly and beneficially, improved gloss performance was achieved by the inventive fixed abrasive sample buffs compared to the conventional method and buff C2.

Similar abrasive testing was conducted for control buff C2 and inventive sample buffs S5, S6, and S7. FIGS. 17A, 17B, 17C, and 17D show surface gloss (20°), surface finish (Ra), power draw (hp), and surface finish (Rz) for inventive sample buffs S6 compared to control buff C2 on workpieces having the same surface roughness type. Sample buff S6 was first tested under dry conditions at 7500 SFPM (S6 Dry 7500 rpm), then under dry conditions at 9000 SFRPM (S6 Dry 9000), and then water was sprayed onto the buff to cool the remainder of the buffing process (S6 Wet 9000). Again, unexpected and beneficially improved gloss performance was achieved by the inventive fixed abrasive sample buffs compared to the conventional buff C2.

FIGS. 18A, 18B, and 18C show bar graphs displaying surface gloss (20°), surface finish (Ra), and surface finish (Rz) comparisons for inventive abrasive buff samples S5, S6, and S7 compared to control buff C2. All inventive sample buffs achieved improved gloss performance and comparable surface roughness.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Claims

1. An abrasive buff comprising:

a plurality of woven fabric layers; and

an abrasive composition fixed to each of the fabric layers,

wherein each of the fabric layers comprises a plurality of yarns,

wherein the abrasive composition is disposed at least partially within the yarns, and

wherein the abrasive composition comprises: a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder.

2. The abrasive buff of claim 1, wherein the abrasive composition comprises:

15 wt % to 90 wt % of the abrasive buff.

3. The abrasive buff of claim 1, wherein fabric layers comprise:

10 wt % to 85 wt % of the abrasive buff.

4. The abrasive buff of claim 1, wherein the woven fabric layer comprises a woven cloth.

5. The abrasive buff of claim 4, wherein the woven cloth comprises a thread count in a range from 50 to 300 threads per inch in the warp direction.

6. The abrasive buff of claim 4, wherein the woven cloth comprises a thread count in a range from 50 to 300 threads per inch in the weft direction.

7. The abrasive buff of claim 4, wherein woven cloth comprises a ratio of warp thread count to weft thread count ranging from 1:1.8 to 1:1.

8. The abrasive buff of claim 4, wherein the woven cloth comprises fibers having a linear density in a range of 0.1 denier to 500 denier.

9. The abrasive buff of claim 1, wherein the fabric comprises a weight of grams per square meter (“GSM”) in a range of 100 to 800 GSM.

10. The abrasive buff of claim 1, wherein the fabric comprises synthetic fibers, natural fibers, or a combination thereof.

11. The abrasive buff of claim 1, wherein the woven fabric layer is coated with the abrasive composition on a first side.

12. The abrasive buff of claim 11, wherein the woven fabric layer is further coated with the abrasive composition on a second side.

13. The abrasive buff of claim 1, wherein the abrasive composition comprises:

20 wt % to 90 wt % of abrasive grains and

10 wt % to 80 wt % of a polymeric binder composition.

14. The abrasive buff of claim 13, wherein the abrasive composition further comprises:

0.1 wt % to 10 wt % of a rheology modifier.

15. The abrasive buff of claim 14 wherein the rheology modifier comprises a cellulose compound, a fumed silica, or a combination thereof.

16. The abrasive buff of claim 12, wherein the abrasive composition is disposed through the fabric between the yarns from the first side of the fabric to the second side of the fabric.

17. The abrasive buff of claim 12, wherein the abrasive composition is disposed between the fibers of the woven fabric layer.

18. The abrasive buff of claim 1, wherein the polymeric binder is flexible.

19. The abrasive buff of claim 1, wherein the polymeric binder has a glass transition temperature (Tg) of not greater than 10° C.

20. An abrasive buff comprising:

a plurality of fabric layers; and

an abrasive composition fixed to each of the fabric layers,

wherein the abrasive composition is disposed at least partially within each of the fabric layers,

wherein the abrasive composition comprises a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder, and

wherein the polymeric binder the polymeric binder has a glass transition temperature (Tg) of not greater than 10° C.