ABRASIVE ARTICLES HAVING IMPROVED PERFORMANCE

The present disclosure relates to an abrasive article. The abrasive article (10) includes a non-woven web (12). The non-woven web (12) includes a fiber or filament component (18). The non-woven web (12) further includes a first major surface (14) and a second major surface (16). A thickness of the non-woven web (12) is defined from the first major surface (14) to the second major surface (16). The abrasive article further includes a plurality of shaped abrasive particles (22) dispersed through at least a portion of the non-woven web (12). The abrasive article further includes a heat-activated water-forming inorganic component dispersed through the non-woven web (12).

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Description
BACKGROUND

Non-woven abrasive articles generally have a non-woven web (e.g., a lofty, open, fibrous web), abrasive particles, and a binder material (commonly termed a “binder”) that bonds the fibers within the non-woven web to each other and secures the abrasive particles to the non-woven web.

SUMMARY OF THE DISCLOSURE

Various embodiments of the present disclosure relate to an abrasive article.

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

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

Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a hydrated aluminum compound dispersed through the non-woven web. About 5% to about 70% of the plurality of shaped abrasive particles comprise a tip oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces.

Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a hydrated aluminum compound dispersed through the non-woven web. A portion of the plurality of shaped abrasive particles comprising a face oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces is in a range of from about 5% to about 70% of the plurality of shaped abrasive particles.

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

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

BRIEF DESCRIPTION OF THE FIGURES

The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

FIG. 1 is a perspective view of an abrasive article.

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

FIGS. 3A-3D are schematic diagrams of shaped abrasive particles having a planar trigonal shape, in accordance with various embodiments.

FIGS. 4A-4E are schematic diagrams of shaped abrasive particles having a tetrahedral shape, in accordance with various embodiments.

FIG. 5 is a graph showing the depth of penetration of shaped abrasive particles in a nonwoven web, in accordance with various embodiments.

FIG. 6 is a graph showing the depth of penetration of shaped abrasive particles in a nonwoven web, in accordance with various embodiments.

FIG. 7 is a graph showing the depth of penetration of shaped abrasive particles in a nonwoven web, in accordance with various embodiments.

 DETAILED DESCRIPTION

Reference will now be made in detail to certain embodiments of the disclosed subject matter, examples of which are illustrated in part in the accompanying drawings. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

In the methods described herein, the acts can be carried out in any order without departing from the principles of the disclosure, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range.

The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

As used herein “shaped abrasive particle” means an abrasive particle having a predetermined or non-random shape. One process to make a shaped abrasive particle such as a shaped ceramic abrasive particle includes shaping the precursor ceramic abrasive particle in a mold having a predetermined shape to make ceramic shaped abrasive particles. Ceramic shaped abrasive particles, formed in a mold, are one species in the genus of shaped ceramic abrasive particles. Other processes to make other species of shaped ceramic abrasive particles include extruding the precursor ceramic abrasive particle through an orifice having a predetermined shape, printing the precursor ceramic abrasive particle though an opening in a printing screen having a predetermined shape, or embossing the precursor ceramic abrasive particle into a predetermined shape or pattern. In other examples, the shaped ceramic abrasive particles can be cut from a sheet into individual particles. Examples of suitable cutting methods include mechanical cutting, laser cutting, or water-jet cutting. Non-limiting examples of shaped ceramic abrasive particles include shaped abrasive particles, such as triangular plates, or elongated ceramic rods/filaments. Shaped ceramic abrasive particles are generally homogenous or substantially uniform and maintain their sintered shape without the use of a binder such as an organic or inorganic binder that bonds smaller abrasive particles into an agglomerated structure and excludes abrasive particles obtained by a crushing or comminution process that produces abrasive particles of random size and shape. In many embodiments, the shaped ceramic abrasive particles comprise a homogeneous structure of sintered alpha alumina or consist essentially of sintered alpha alumina.

FIG. 1 is a perspective view of abrasive article 10. FIG. 2 is a sectional view of the abrasive article of FIG. 1 taken along section line 2-2. FIGS. 1 and 2 show substantially the same components and are discussed concurrently. As shown in FIGS. 1 and 2, abrasive article 10 includes non-woven web 12. Non-woven web 12 includes first major surface 14 and opposite second major surface 16. Each of first major surface 14 and second major surface 16 have an irregular or substantially non-planar profile, although in other embodiments either surface may be planar. Non-woven web 12 includes fiber component 18, which includes individual fibers 20. Non-woven web 12 further includes abrasive particles 22, which are dispersed throughout non-woven web 12; binder 24 adheres the abrasive particles to individual fibers 20.

While not so limited, fiber component 18 can range from about 5 wt % to about 40 wt % of abrasive article 10, about 10 wt % to about 25 wt %, about 10 wt % to about 20 wt %, about 12 wt % to about 15 wt %, less than, equal to, or greater than about 5 wt %, 10, 15, 20, 25, 30, 35, or 40 wt %. Fiber component 18 can include a plurality of individual fibers 20 that are randomly oriented and entangled with respect to each other. Individual fibers 20 are bonded to each other at points of mutual contact. Individual fibers 20 can be staple fibers or continuous fibers. As generally understood, “staple fiber” refers to a fiber of a discrete length and “continuous fiber” refers to a fiber that can be any suitable fiber or filament such as a synthetic filament, or an inorganic fiber such as a steel filament, a glass fiber, a basalt fiber. The steel can be a stainless steel, a carbon steel, or include metal such as copper or alloys such as brass. Individual fibers 20 can range from about 70 wt % to about 100 wt % of fiber component 18, about 80 wt % to about 90 wt %, less than, equal to, or greater than about 70 wt %, 75, 80, 85, 90, 95, or 100 wt % of fiber component 18. In further embodiments, non-woven web 12 can be free of fiber component 18 or individual fibers 20 and can instead include a sponge or foam material that includes random or ordered cavities.

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

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

In examples of the abrasive article including blends of individual staple fibers, the first and second pluralities of individual staple fibers can account for different portions of fiber component 18. For example, a first plurality of individual fibers 20 can range from about 20 wt % to about 80 wt % of fiber component 18, about 30 wt % to about 40 wt %, less than, equal to, or greater than about 20 wt %, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt %. A second plurality of individual fibers 20 can range from about 20 wt % to about 80 wt % of fiber component 18, about 60 wt % to about 70 wt %, less than, equal to, or greater than about 20 wt %, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt %. While two pluralities of individual staple fibers are discussed herein, it is within the scope of this disclosure to include additional pluralities of individual staples fibers such as a third plurality of individual staple fibers that differs with respect to at least one of liner density value, crimp index, and/or length of the first and second pluralities of individual fibers 20.

Individual fibers 20 of non-woven web 12 can include many suitable materials. Factors influencing the choice of material include whether that material is suitably compatible with adhering binders and abrasive particles 22 while also being processable in combination with other components of abrasive article 10, and the material's ability to withstand processing conditions (e.g., temperatures) such as those employed during application and curing of the binder. The materials of fibers 20 can also be chosen to affect properties of abrasive article 10 such as, for example, flexibility, elasticity, durability or longevity, abrasiveness, and finishing properties. Examples of fibers 20 that may be suitable include natural fibers, synthetic fibers, and mixtures of natural and/or synthetic fibers. Examples of synthetic fibers include those made from polyester (e.g., polyethylene terephthalate), nylon (e.g., nylon-6,6, polycaprolactam), polypropylene, acrylonitrile (e.g., acrylic), rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, polyester (e.g., polyester terephthalate) and vinyl chloride-acrylonitrile copolymer. Examples of suitable natural fibers include cotton, wool, jute, and hemp. Some individual fibers 20 can include an inorganic material a steel, a glass, or a basalt. The steel can be a stainless steel, a carbon steel, or include metal such as copper or alloys such as brass. Individual fibers 20 may be of virgin material or of recycled or waste material, for example, reclaimed from garment cuttings, carpet manufacturing, fiber manufacturing, or textile processing. Individual fibers 20 may be homogenous or a composite such as a bicomponent fiber (e.g., a co-spun sheath-core fiber). Individual fibers 20 can be tensilized and crimped staple fibers.

In some examples, individual fibers 20 can have a non-circular cross sectional shape or blends of individual fibers 20 having a circular and a non-circular cross sectional shape (e.g., triangular, delta, H-shaped, tri-lobal, rectangular, square, dog bone, ribbon-shaped, or oval).

Abrasive article 10 includes an abrasive component including shaped abrasive particles 22 adhered to individual fibers 20. Shaped abrasive particles 22 can range from about 5 wt % to about 70 wt % of abrasive article 10, about 40 wt % to about 60 wt %, less than, equal to, or greater than about 5 wt %, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70 wt %.

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

Shaped abrasive particles 22 can be applied to the fibers as individual abrasive particles (e.g., particles 22 not held together with a binder and applied to fibers 20) or as agglomerates (e.g., particles 22 held together with a binder and applied to fibers 20). Some agglomerates can include particles 22 that are glass bonded or resin bonded. The agglomerates can include crushed abrasive particles, particles 22.

Shaped abrasive particles 22 include any particle or particles with at least a portion of the abrasive particle having a predetermined shape. The predetermined shape can be replicated, for example, from a mold cavity that is used to form the shaped precursor abrasive particle. In embodiments where shaped abrasive particles 22 are formed in a mold cavity, the predetermined geometric shape may substantially replicate the mold cavity used to form the shaped abrasive particles 22. Shaped abrasive particles 22 may also replicate a shape of a die in examples where a shaped abrasive particle 22 is formed through extrusion. Shaped abrasive particles 22 may also replicate a shape found in a program, for example, a computer-aided-design (CAD) program, if shaped abrasive particles 22 or abrasive article 10 is formed through an additive manufacturing process. Shaped abrasive particles 22 do not refer to randomly sized crushed abrasive particles formed, for example, by a mechanical crushing operation.

As an example of shaped abrasive particles 22 having a planar trigonal shape, FIGS. 3A-3B show trigonal shaped abrasive particle 22 bounded by trigonal base 30, trigonal top 32, and a plurality of sidewalls 34A, 34B, 34C connecting base 30 and top 32. Base 30 has tips 36A, 36B, 36C having an average radius of curvature of less than 50 micrometers. FIGS. 3C-3D show one face of shaped abrasive particles 22 to better show the radius of curvature for tip 36A. In general, the smaller the radius of curvature, the sharper the sidewall edge will be. In some cases, the base and the top of the shaped abrasive particles are substantially parallel, resulting in prismatic or truncated pyramidal (as shown in FIGS. 3A-3B) shapes, although this is not a requirement. As shown, sidewalls 34A, 34B, and 34C have equal dimensions and form dihedral angles with base 30 of about 82 degrees. However, it will be recognized that other dihedral angles (including 90 degrees) can also be used. For example, the dihedral angle between the base and each of the sidewalls can independently range from 45 to 90 degrees, 70 to 90 degrees, or 75 to 85 degrees.

FIGS. 4A-4E show examples of shaped abrasive particles 22 having a tetrahedral shape. As shown in FIGS. 4A-4E, tetrahedral shaped abrasive particles 22 are shaped as regular tetrahedrons. As shown in FIG. 4A, tetrahedral shaped abrasive particle 22A has four faces (42A, 44A, 46A, and 48A) joined by six edges (50A, 52A, 54A, 56A, 58A, and 60A) terminating at four tips (62A, 64A, 66A, and 68A). Each of the faces contacts the other three faces at the edges. While a regular tetrahedron (e.g., having six equal edges and four faces) is depicted in FIG. 4A, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22A can be shaped as irregular (e.g., having edges of differing lengths) tetrahedrons.

Referring now to FIG. 4B, tetrahedral shaped abrasive particle 22B has four faces (42B, 44B, 46B, and 48B) joined by six edges (50B, 52B, 54B, 56B, 58B, and 60B) terminating at four tips (62B, 64B, 66B, and 68B). Each of the faces is concave and contacts the other three faces at respective common edges. While a particle with tetrahedral symmetry (e.g., four rotational axes of threefold symmetry and six reflective planes of symmetry) is depicted in FIG. 4B, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22B can have one, two, or three concave faces with the remainder being planar.

Referring now to FIG. 4C, tetrahedral shaped abrasive particle 22C has four faces (42C, 44C, 46C, and 48C) joined by six edges (50C, 52C, 54C, 56C, 58C, and 60C) terminating at four tips (62C, 64C, 66C, and 68C). Each of the faces is convex and contacts the other three faces at respective common edges. While a particle with tetrahedral symmetry is depicted in FIG. 4C, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22C can have one, two, or three convex faces with the remainder being planar or concave.

Referring now to FIG. 4D, tetrahedral shaped abrasive particle 22D has four faces (42D, 44D, 46D, and 48D) joined by six edges (50D, 52D, 54D, 56D, 58D, and 60D) terminating at four tips (62D, 64D, 66D, and 68D). While a particle with tetrahedral symmetry is depicted in FIG. 4D, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22D can have one, two, or three convex faces with the remainder being planar.

Deviations from the depictions in FIGS. 4A-4D can be present. An example of such a tetrahedral shaped abrasive particle 22E is depicted in FIG. 4E, showing tetrahedral shaped abrasive particle 22E that has four faces (40E, 44E, 46E, and 48E) joined by six edges (50E, 52E, 54E, 56E, 58E, and 60E) terminating at four tips (62E, 64E, 66E, and 68E). Each of the faces contacts the other three faces at respective common edges. Each of the faces, edges, and tips has an irregular shape.

Any of shaped abrasive particles 22 can include any number of shape features. The shape features can help to improve the cutting performance of any of shaped abrasive particles 22. Examples of suitable shape features include an opening, a concave surface, a convex surface, a groove, a ridge, a fractured surface, a low roundness factor, or a perimeter comprising one or more corner points having a sharp tip. Individual shaped abrasive particles can include any one or more of these features.

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

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

Shaped abrasive particles 22 can be further oriented on individual fibers 20 such that at least a portion of the total number of shaped abrasive particles 22 include a face that is oriented in a direction substantially perpendicular to a line passing through first and second major surfaces 14 and 16. Additionally, in some embodiments, shaped abrasive particles 22 be disposed in a gap between two of more individual fibers 20 and held in place by a resin in contact with one or more fibers 20. The individual faces can be perfectly perpendicular with the line passing through first and second major surfaces 14 and 16, but the face can also be within about 1 degree to about 20 degrees off of perfect alignment, about 1 degree to about 15 degrees, less than, equal to, or greater than about 1 degree, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or about 20 degrees.

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

Shaped abrasive particles 22 can be distributed throughout the thickness of abrasive article 10. The thickness of abrasive article 10 is defined from first major surface 14 and second major surface 16. In embodiments in which any one or both of first major surface 14 and second major surface 16 have a non-planar or irregular surface, the thickness is measured from the maximum distance between first major surface 14 and second major surface 16. Shaped abrasive particles 22 that are not located at first major surface 14 can be located anywhere from a range of about 5% to about 100% of a thickness of fibrous web 102, about 20% to about 80%, or less than, equal to, or greater than about 5%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or about 100%. The portion of shaped abrasive particles 22 that are not located at first major surface 14 can be in a range of from about 10 wt % to about 100 wt % of shaped abrasive particles 22, about 50 wt % to about 100 wt %, or less than, equal to, or greater than about 10 wt %, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or about 100 wt %.

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

Abrasive article 10 can also include conventional (e.g., crushed) abrasive particles. Examples of useful conventional abrasive particles include any abrasive particles known in the abrasive art. Examples of useful abrasive particles include fused aluminum oxide-based materials such as aluminum oxide, ceramic aluminum oxide (which can 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 conventional abrasive particles can, for example, have an average diameter ranging from about 10 μm to about 2000 μm, about 20 μm to about 1300 μm, about 50 μm to about 1000 μm, less than, equal to, or greater than about 10 μm, 20, 30, 40, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1650, 1700, 1750, 1800, 1850, 1900, 1950, or 2000 μm. For example, the conventional abrasive particles can have an abrasives industry-specified nominal grade. Such abrasives industry-accepted grading standards include those known as the American National Standards Institute, Inc. (ANSI) standards, Federation of European Producers of Abrasive Products (FEPA) standards, and Japanese Industrial Standard (HS) standards. Exemplary ANSI grade designations (e.g., specified nominal grades) include: ANSI 12 (1842 μm), ANSI 16 (1320 μm), ANSI 20 (905 μm), ANSI 24 (728 μm), ANSI 36 (530 μm), ANSI 40 (420 μm), ANSI 50 (351 μm), ANSI 60 (264 μm), ANSI 80 (195 μm), ANSI 100 (141 μm), ANSI 120 (116 μm), ANSI 150 (93 μm), ANSI 180 (78 μm), ANSI 220 (66 μm), ANSI 240 (53 μm), ANSI 280 (44 μm), ANSI 320 (46 μm), ANSI 360 (30 μm), ANSI 400 (24 μm), and ANSI 600 (16 μm). Exemplary FEPA grade designations include P12 (1746 μm), P16 (1320 μm), P20 (984 μm), P24 (728 μm), P30 (630 μm), P36 (530 μm), P40 (420 μm), P50 (326 μm), P60 (264 μm), P80 (195 μm), P100 (156 μm), P120 (127 μm), P120 (127 μm), P150 (97 μm), P180 (78 μm), P220 (66 μm), P240 (60 μm), P280 (53 μm), P320 (46 μm), P360 (41 μm), P400 (36 μm), P500 (30 μm), P600 (26 μm), and P800 (22 μm). An approximate average particles size of reach grade is listed in parenthesis following each grade designation.

Shaped abrasive particles 22 or crushed abrasive particles can include any suitable material or mixture of materials. For example, shaped abrasive particles 22 can include a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol-gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof. In some embodiments, shaped abrasive particles 22 and crushed abrasive particles can include the same materials. In further embodiments, shaped abrasive particles 22 and crushed abrasive particles can include different materials.

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

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

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

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

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

It was surprisingly found that including a heat-activated water-forming inorganic component such as a hydrated aluminum compound with shaped abrasive particles 22, improves grinding performance in abrasive articles. For example, abrasive articles including a hydrated aluminum compound were found to increase grinding performance in abrasive articles used to abrade carbon steel. Additionally, it was surprisingly found that abrasive articles that included a hydrated aluminum compound had a higher percentage of shaped abrasive particles 22 having a tip oriented in an upright position (e.g., substantially parallel to a line extending through first major surface 12 and second major surface 14) than a corresponding abrasive article differing only by being free of aluminum hydrate. Additionally, it was surprisingly found that abrasive articles that included a hydrated aluminum compound had shaped abrasive particles 22 that were able to penetrate the abrasive article 10 to a deeper percentage of the thickness of the abrasive article 10 than a corresponding abrasive article differing only by being free of aluminum hydrate. Additionally, it was surprisingly found that abrasive articles that included a hydrated aluminum compound had shaped abrasive particles that were evenly distributed through the abrasive article 10. It was further surprisingly found that included the hydrated aluminum compound alone or with crushed abrasive particles did not produce abrasive articles that performed as well as those including shaped abrasive particles 22 and the hydrated aluminum compound.

In some embodiments, abrasive article 10 can include a flexible backing in contact with first major surface 12 or second major surface 14. A flexible backing can be used to impart strength to the abrasive article 10. A flexible backing can also be used to affix a logo or other visual media to the abrasive article 10. Examples of suitable flexible backings include a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, a staple fiber, a continuous fiber, a non-woven, a foam, a screen, a laminate, and combinations thereof.

Abrasive article 10 can be made by forming a non-woven web and applying adhesive to fiber component 18. A make coat can be applied to non-woven web 12. Non-woven web 12 can be rolled to substantially lay at least some fibers 20 flat that protrude from web 12. Abrasive particles 22 can be applied to the make coat to form the non-woven abrasive web 12. The make coat is cured and an optional size coat may be applied over the make coat, which is subsequently cured to form the abrasive article 10.

In some embodiments, a scrim or reinforcing layer can be attached to nonwoven abrasive web 12. The scrim can include any suitable material such a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, a vulcanized fiber, a nonwoven, a foam, a screen, a laminate, or combinations thereof. The scrim can be attached to nonwoven web 12 by needle tacking, needle punching, or through a binder.

The non-woven web 12 can be manufactured, for example, by conventional air laid, carded, stitch bonded, spun bonded, wet laid, and/or melt blown procedures. Air laid non-woven webs can be prepared using a web-forming machine such as, for example, that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web can also be perforated. In some examples, perforating the web can include needle-punching the web.

A non-woven abrasive web is prepared by adhering abrasive particles 22 to non-woven web 12 with a curable second binder. Binders useful for adhering abrasive particles 22 to non-woven web 12 can be selected according to the final product requirements. Examples of binders include those comprising polyurethane resin, phenolic resin, acrylate resin, and blends of phenolic resin, urea formaldehyde, latex, epoxy novolac, epoxy resin, and acrylate resin. The coating weight for abrasive particles 22 can depend, for example, on the particular binder used, the process for applying abrasive particles 22 (e.g., spraying), and the size of the abrasive particles 22. For example, the coating weight of abrasive particles 22 on non-woven web 12 can be 100 grams per square meter (g/m2) to about 5000 g/m2, about 1500 g/m2 to about 5000 g/m2 about 2000 g/m2 to about 4000 g/m2, less than, equal to, or greater than about 100 g/m2, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600, 3700, 3800, 3900, 4000, 4100, 4200, 4300, 4400, 4500, 4600, 4700, 4800, 4900, or 5000 g/m2. Abrasive particles 12 can be coated on either or both of the first and second major surfaces of non-woven web 12. Abrasive particles 22 can be coated to achieve a substantially uniform distribution of shaped abrasive particles 22 throughout the web 12.

Additionally, components such as the heat-activated water-forming inorganic components can be contacted with non-woven web 12. In some embodiments, certain components of abrasive article 10 can be included in a slurry. For example, a slurry can include shaped abrasive particles 22, the heat-activated water-forming inorganic component, the materials of the make coat and the size coat, crushed abrasive particles or any other component or sub-combination of components. The slurry can be stored and applied directly to non-woven web 12.

Abrasive article 10 can be used to remove a material from a surface of a workpiece. This can be accomplished by contacting a surface of abrasive article 10 against the workpiece. The workpiece can be contacted, for example, at a force ranging from about 1 newton to about 40 newtons. Abrasive article 10 can then be moved (e.g., rotated) relative to the workpiece, while maintaining a pressure between abrasive article 10 and the workpiece surface. While abrasive article 10 can have many suitable shapes, an example of a suitable shape is a disc. Abrasive article 10 can be adapted to remove many different types of materials. Examples of such materials include carbon steel, stainless steel, aluminum, or a polymeric material such as a polymeric surface coating on the workpiece.

It was surprisingly found that a greater amount of the workpiece was removed than is removed by a corresponding abrasive article run at the same speed and differing only by having less heat-activated water-forming inorganic component or no heat-activated water-forming inorganic component. It was further surprisingly found that abrasive articles including heat-activated water-forming inorganic components were particularly effective in abrading carbon steel.

EXAMPLES

Objects and benefits of this disclosure are further illustrated by the following non-limiting examples. Particular materials and amounts thereof recited in these examples, however, as well as other conditions and details, should not be construed to unduly limit this disclosure.

The following unit abbreviations are used to describe the examples:

° C.: degrees Centigrade

cm: centimeter

g/m2: grams per square meter

inch: 1 inch=2.54 centimeter

mm: millimeter

Unless stated otherwise, all reagents were obtained or are available from chemical vendors such as Sigma-Aldrich Company, St. Louis, Mo., or may be synthesized by known methods. Unless otherwise reported, all ratios and percentages are by weight.

In the Examples that follow, the materials are referred to as follows:

Abbreviation Description F1 Nylon 6,6 58 denier × 53.3 mm staple fibers, obtained as FIBER 12 from 3M Company SCR 16 × 16 nylon 840d warp and weft scrim from Highland Industries, Kernersville, NC PU1 blocked urethane prepolymer, obtained as “ADIPRENE BL16” from Chemtura Corporation, Middlebury, Connecticut CUR aromatic amine curative, obtained as “RAC-9907” from Royce international, East Rutherford, New Jersey PMA propylene glycol monomethyl ether, obtained as “DOWANOL PMA” from Dow Chemical Company, Midland, Michigan PME 1-methoxy 2-propanol obtained as “DOWANOL PM Glycol Ether” from Dow Chemical Company, Midland, Michigan PF1 Phenolic resin 80 0701A from Arclin, Ontario, Canada CC calcium carbonate, obtained as “HUBERCARB Q325” from Huber Engineered Materials, Quincy, Illinois LiSt lithium stearate, obtained as “LIC 17” from Baerlocher USA, Cincinnati, Ohio ASIL2 amorphous silica, obtained as “CAB-O-SIL M-5” from Cabot Corporation, Cambridge, Massachusetts CB carbon black, obtained as “RAVEN 16 POWDER” from Columbian Chemicals Corporation, Marietta, Georgia PL oligameric diamine, Versalink P650 obtained from Air Products, Allentown, PA LUB hydrocarbon distillate as Ace-Lube 23N from LubeTech, St Paul, MN MIN1 aluminum oxide, obtained as “ALODUR BFRPL, GRADE 150” from Treibacher Schleifmittel GmbH, Villach, Austria MIN2 aluminum oxide, obtained as “ALODUR BFRPL, GRADE 180” from Treibacher Schleifmittel GmbH, Villach, Austria PSG Shaped abrasive particles were prepared according to the disclosure of U.S. Pat. No. 8,142,531 (Adefris et al.). The shaped abrasive particles were prepared by molding alumina sol gel in equilateral triangle-shaped polypropylene mold cavities. After drying and firing, the resulting shaped abrasive particles were about 0.26 mm (side length) × 0.06 mm thick, with a draft angle of approximately 98 degrees. CUB1 Grade 150 crushed ceramic grain, obtained as Cubitron ™ 321 from 3M Company, St Paul, MN ATH1 aluminum trihydrate (Al(OH)3), obtained as Martinal 107 IO from Huber Engineered Materials, Atlanta, Georgia ATH2 aluminum trihydrate (Al(OH)3), obtained as SB432 from Huber Engineered Materials, Atlanta, Georgia ATH3 aluminum trihydrate (Al(OH)3), obtained as Hymod ® SB432 SG from Huber Engineered Materials, Atlanta, Georgia ATH4 aluminum trihydrate (Al(OH)3), obtained as Hymod ® SB432 SH from Huber Engineered Materials, Atlanta, Georgia ATH5 aluminum trihydrate (Al(OH)3), obtained as Hymod ® 9400 from Huber Engineered Materials, Atlanta, Georgia ATH6 aluminum trihydrate (Al(OH)3), obtained as Hymod ® 9400 SF from Huber Engineered Materials, Atlanta, Georgia ATH7 aluminum trihydrate (Al(OH)3), obtained as Hymod ® 9400 SP from Huber Engineered Materials, Atlanta, Georgia ATH8 aluminum trihydrate (Al(OH)3), obtained as Hymod ® 9400 SG from Huber Engineered Materials, Atlanta, Georgia ATH9 aluminum trihydrate (Al(OH)3), obtained as AH255 from R J Marshall, Southfield, MI. ATH10 aluminum trihydrate (Al(OH)3), obtained as A208 from R J Marshall, Southfield, MI. ATH11 aluminum trihydrate (Al(OH)3), obtained as MX100 from R J Marshall, Southfield, MI. MDH1 Magnesium dihydroxide (Mg(OH)2), obtained as Vertex 100 from Huber Engineered Materials, Atlanta, Georgia MDH2 Magnesium dihydroxide (Mg(OH)2), obtained as Vertex 100 SA from Huber Engineered Materials, Atlanta, Georgia Boehmite AlO(OH), obtained as Disperal from Sasol, Johannesburg, South Africa Alumina Al2O3, obtained as calcined alumina from Almatis, Leetsdale, PA PAF potassium aluminum fluoride, obtained as potassium aluminum fluoride from KBM Affilips B.V., Netherlands KBF4 potassium boron fluoride, obtained as Potassium Fluoroborate Spec 101 from AWSM Industries, a Division of Royale Pigments & Chemicals Inc., Paramus, NJ K2B10O16 potassium borate decahydrate, obtained as borax decahydrate from U.S. Borax Inc., Greenwood Village, CO WC amine functionalized wollostonite, obtained as calcium silicate 10014 silane from Nyco Minerals, Willsboro, New York

Grinding Performance Example 1

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven. Table 1:

TABLE 1 Compositions of Examples 1-9 Prebond Example 1 Example 2 Example 3 Example 4-9 Material Coating Slurry Coat PME — 17.6% 16.5% 17.6% 14.9%  PU1 48.9% — — — — CUR  7.6% — — — — PMA 20.6% — — — — CaCO3 19.2% — — — — LiSt  1.9% — — — — PF1 — 21.5% 20.1% 21.5% 20.5%  GEO — — — — — CB  1.9% — — ASIL2 —  0.3%  0.3%  0.3% 0.3% MIN1 — 28.2% 26.4% 25.3% 24.2%  MIN2 — 28.2% 26.4% 25.3% 24.2%  PSG — —  5.6% 5.4% FIL — —  6.2% 6.3% PL —  2.3%  2.2%  2.3% 2.2% LUB —  2.0%  1.9%  2.0% 1.9%

Example 2

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven.

Example 3

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven.

Example 4

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Example 5

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of PAF was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Example 6

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of WC was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Example 7

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of CC was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Example 8

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of KBF4 was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Example 9

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of K2B10O16 was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

TABLE 2 Compositions of Examples 10-14 Prebond Example 10 Example 11 Example 12-14 Material Coating Slurry Coat PME — 17.6% 14.9%  14.9%  PU1 48.9% — — — CUR  7.6% — — — PMA 20.6% — — — CaCO3 19.2% — — — LiSt  1.9% — — — PF1 — 21.5% 20.5%  20.5%  GEO — — — — CB  1.9% — ASIL2 —  0.3% 0.3% 0.3% MIN1 — 25.3% 24.2%  24.2%  MIN2 — 25.3% 24.2%  24.2%  PSG — — — 5.4% CUB1 — 5.6 5.4% Fill — — 6.3% 6.3% PL —  2.3% 2.2% 2.2% LUB —  2.0% 1.9% 1.9%

Example 10

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 2 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven.

Example 11

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 2 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven.

Example 12

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of alumina was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Example 13

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of boehmite was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Example 14

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of MDH1 was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.

Test Methods Off Hand

3″ diameter discs were fitted with Roloc™ attachment. A carbon steel test panel as well as an aluminum test panel were abraded with a coated abrasive belt corresponding to any of Examples 1-12 on backstand to impose a linear grain on the test piece. The average Ra is 75 pin on carbon steel and 150 pin on aluminum test panels. The panel and disc are then weighed before testing.

Off Hand Short Test

For one minute, working in the direction of the grain of the respective panel, scratches were removed from half of the panel with the nonwoven disc according to any one of Examples 1-12. For a second one-minute period, working in the direction of the grain, the scratches were removed from the second half of the panel. The disc and workpiece were then cleaned and weighed. The Ra of the panel was also measured in 5 discreet areas and recorded.

Off Hand Long Test

For one minute, working in the direction of the grain of the respective panels, scratches were removed from half of the panel with the nonwoven disc according to any one of Examples 1-12. For a second one-minute period, working in the direction of the grain, the scratches were removed from the second half of the panel.

The panel was weighed before and after the 2-minute period to determine the mass loss of the panel.

A new panel was used for another 2 minutes with the methodology used above.

This process was continued for 4 panels—8 minutes of total off hand grinding time for each disc. The surface finish was measured on the first panel and the fourth panel in 5 discreet areas per panel. The highest and lowest surface finish numbers were discarded and the middle 3 Ra numbers were averaged. The average surface finish from panel 1 and panel 4 were averaged to give the final surface finish number recorded below.

XY Auto Test

3″ diameter discs were fitted with Roloc™ attachment. The XY tested the disc for 8 cycles. Each cycle was 1 minute long in which the disc abraded a flat test panel. During the testing a robotic arm moved in the X and Y directions abrading the surface of the panel. The Ra that the disc left behind was checked after the first cycle and after cycle #8 in 5 discreet areas. The panel and disc were weighed before cycle 1 and after cycle 8 to determine the substrate and disc mass loss.

Force and RPM used when abrading carbon steel was either 5 lbs and 9000 RPM or 10 lbs and 11,000 RPM.

Force used when abrading aluminum was either 5 lbs and 9,000 RPM or 5 lbs and 11,0000 RPM.

TABLE 3 Results for tests run on carbon steel substrate XY Auto Off Hand Short Off Hand Long Surface Surface Surface Normalized Cut % % Finish Cut Cut % % Finish Cut Cut % % Finish Example Cut Increase Wear Ra (uin) (g) Increase Wear Ra (uin) (g) Increase Wear Ra (uin) 1 1.00 — 3.3 11.0 1.00 — 2.6 15.8 13.40 — 4.5 14.7 2 1.06  6% 4.0 9.0 1.01  1% 2.8 15.1 13.30  −1% 3.5 14.6 3 0.99  −1% 3.1 15.0 0.91  −9% 1.6 14.7 13.70  2% 5.7 13.6 4 1.47  47% 3.1 16.0 1.29  29% 2.8 18.6 20.50  53% 5.1 17.9 5 0.70 −30% 1.8 12.0 0.86 −14% 1.6 16.0 13.20  −1% 5.2 14.5 6 0.99  −1% 30.5 17.5 0.90 −10% 0.9 16.7 — — — — 7 0.83 −17% 33.3 18.7 0.90 −10% 0.9 17.2 — — — — 8 0.70 −30% 2.4 14.2 0.85 −15% 2.2 18.0 0.89 −11% 8.4 16.0 9 0.45 −55% 2.2 12.3 0.67 −33% 2.3 17.0 0.70 −30% 11.0  16.0 10 0.89 −11% 3.0 14.7 0.88 −12% 3.7 12.4 — — — — 11 1.14  14% 3.0 15.2 0.86 −14% 3.4 11.4 — — — — 12 0.71 −29% 2.0 15.9 0.79 −21% 2.6 21.7 0.90 −10% 8.1 21.0 13 0.90 −10% 2.3 15.2 1.10  10% 2.4 15.3 1.00  0% 6.9 15.0 14 0.68 −32% 2.0 15.0 0.84 −16% 2.5 16.0 1.01  1% 5.9 15.7

TABLE 4 Results for tests run on aluminum substrate XY Auto Off Hand Short Surface Surface Normalized Cut % % Finish Cut Cut % % Finish Example Cut Increase Wear Ra (uin) (g) Increase Wear Ra (uin) 1 1.00 — 31.3 33.1 1.00 — 11.2 52.0 2 0.99 −1%  30.1 32.0 0.95 −0.05 14.4 53.5 3 1.06 6% 28.0 39.5 0.95 −0.05 9.6 54.8 4 1.21 21%  32.4 41.1 1.03 0.03 11.2 59.5 5 1.05 5% 30.6 35.6 1.02 0.02 11.0 44.3 6 1.09 9% 36.1 48.9 1.08 0.08 11.3 49.7 7 1.00 0% 35.9 56.5 1.03 0.03 11.3 45.7 8 1.11 11%  30.5 39.5 1.10 0.10 13.0 54.0 9 0.86 −14%  34.6 29.9 1.07 0.07 13.8 59.0 10 0.98 −2%  28.6 31.3 0.90 −0.10 13.5 34.8 11 0.93 −7%  30.0 29.6 0.94 −0.06 14.1 33.8 12 0.97 −3%  28.2 35.2 — — — — 13 1.00 0% 27.7 31.5 — — — — 14 1.00 0% 29.2 34.2 — — — —

Abrasive Article Construction

TABLE 5 Compositions of Examples 15-17 Prebond Example 15 Example 16 Example 17 Material Coating Slurry Coat PME — 17.6% 16.5%  14.4% PU1 48.9% — — — CUR  7.6% — — — PMA 20.6% — — — CaCO3 19.2% — — — LiSt  1.9% — — — PF1 — 21.5% 20.1%  17.6% GEO — — — — CB  1.9% — — — PIG1 — — — ASIL2 —  0.3% 0.3%  0.3% MIN1 — 25.3% 23.7%  20.8% MIN2 — 25.3% 23.7%  20.8% PSG —  5.6% 5.3%  4.6% Fill — 6.2% 17.6% PL —  2.3% 2.2%  1.9% LUB —  2.0% 1.9%  1.6%

Example 15

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 5 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition set forth in Table 5 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven.

Example 16

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 5 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition set forth in Table 5 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt % to the slurry spray. The abrasive-coated web was then cured in an oven.

Example 17

A lofty, random air-laid web, having F1 Fibers at a weight of ˜314 g/m2, was formed using equipment such as that available under the trade designation “RANDO WEBBER” commercially available from Rando Machine Company of Macedon, N.Y. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 5 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g/m2. The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition set forth in Table 5 was applied at a dry add-on weight of 1252.9 g/m2 to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 17.6 wt % to the slurry spray. The abrasive-coated web was then cured in an oven.

TABLE 6 Results for Tests Run on Carbon Steel XY Auto Off Hand Short Surface Surface Normalized Cut % % Finish Normalized Cut % % Finish Example Cut Increase Wear Ra (uin) Cut Increase Wear Ra (uin) 15 1.00 — 3.1 14.5 1.00 — 2.6 16.6 16 1.45 45 3.2 20.0 1.32 32 3.8 17.0 17 1.97 97 3.7 16.7 1.52 52 4.1 19.0

TABLE 7 Results for Tests Run on Aluminum XY Auto Off Hand Short Surface Surface Normalized Cut % % Finish Normalized Cut % % Finish Example Cut Increase Wear Ra (uin) Cut Increase Wear Ra (uin) 15 1.00 — 24.2 35.6 1.00 — 11.6 42.6 16 1.16 16 25.5 44.8 1.05 5 10.1 53.7 17 1.24 24 25.1 47.5 1.16 16 8.9 60.7

Test Methods PSG Orientation

Orientation diagrams for the PSG particle were generated for Examples 15, 16, and 17. The orientation diagrams use the directional cosines of the short/minimum axis (PSG width) and the long/maximum axis (PSG length). The Y component of the minimum axis versus the Z component of the maximum axis of each PSG were plotted. Each point in the diagram is an individual PSG object (i.e., single PSG, PSG cluster, PSG+crushed cluster) and N=# is shown for each plot, where N is the number of PSG objects measured in the scanned dataset. The coordinates (0,0) on the diagram refer to a PSG object with a perfectly upright orientation (preferred orientation). The coordinates (90,90) or (−90,−90) refer to a PSG object with a flat orientation (non-preferred orientation). The values between 0 and 90 on the Max Z axis indicate the angle of the directional cosine with respect to a vector normal to the sample scrim/plane. From the plots, it was possible to determine the % of particles in an upright position (PSG with angle <15° from the normal sample plane) and to determine the % of grains in a flat orientation.

PSG Penetration

X-ray microtomography analysis was used to determine the depth of penetration of PSGs in the nonwoven webs. To carry out the procedure, a strip of material was cut from each abrasive article of Examples 15, 16, and 17. Each Example was scanned using a Skyscan 2211 (Bruker microCT, Kontich, Belgium) X-ray microtomography scanner at a resolution of 6.00 um. Data were collected using X-ray source settings of 70 kV and 110 uA with the energy distribution of the incident beam modified by application of a 0.5 mm aluminum filter. Projected images were recorded at discrete sample rotation angles using a flat panel detector as the sample was rotated through a 360 degree angular range using a 0.10 degree angular step size. Five individual detector frames were averaged per collected projected image. Reconstruction was conducted using computer program NRecon (v 1.6.10, Bruker microCT, Kontich, Belgium) where corrections for X-ray source centering, detector ring artifacts, and beam hardening were employed.

The resulting reconstructed images were subjected to post processing to isolate the location of shaped grains within the scanned specimen. A greyscale threshold permitted isolation of abrasive grain from higher and lower density material in the nonwoven construction. Computer program CT Analyzer (v 1.16.4, Bruker microCT, Kontich, Belgium) was used for initial processing of the reconstructed datasets.

Subsequent size filtering on the thresholded images removed small non-shaped abrasive grains from the images. The thresholded and size-filtered images were analyzed to determine the size, shape, and location (centroid coordinates at X, Y, and Z) of the shaped abrasive grains within the dataset volume. The thresholded and size-filtered images were then saved as a separate dataset for subsequent examination of shaped grain orientation. Computer software Avizo (v 9.5.0, ThermoFisher Scientific, Hillsboro, Oreg.) was used for further processing of the reconstructed data as well as for shaped grain analysis.

The physical location of each shaped abrasive grain in the dataset was identified and the short and long axis of each shaped grain were evaluated. The direction cosines for the normals to the short and long axis were calculated and tabulated.

The thresholded images were subjected to re-slicing along the XZ plane to obtain depth profile images of the dataset using CT Analyzer. The area of the abrasive grains was determined for each depth profile image using Avizo.

Results

Results from the orientation analysis are shown in Table 8.

TABLE 8 Orientation of PSG % PSG in Upright % PSG in Flat Example Orientation Orientation 15 10.0 6.1 16 8.0 5.6 17 11.6 4.2

FIGS. 5-7 show that PSG particles were distributed through the total depth of the nonwoven webs. Moreover, PSGs were be distributed within a plurality of regions. That is, there was a region or regions having a higher concentration of PSGs along the depth of the nonwoven web. Representative regions had substantially the same concentration of PSGs or each region or had different concentrations. Table 9 shows the concentration of PSG in Examples 15-17 across the total thickness of the abrasive article, specifically Table 9 shows the wt % of particles in a region accounting for the top third of the total thickness; a region accounting for the middle third of the total thickness; and a region accounting for the bottom third of the total thickness. Table 10 shows the wt % of particles in a region accounting for the top half of the total thickness and a region accounting for the bottom half of the total thickness.

TABLE 9 Wt % PSG of Wt % PSG of Wt % PSG of Example 15 Example 16 Example 17 Top Third of 34.8 40.9 13.7 Total Thickness Middle Third of 30.6 20.6 19.5 Total Thickness Bottom Third of 36.5 39.0 68.4 Total Thickness

TABLE 10 Wt % PSG of Wt % PSG of Wt % PSG of Example 15 Example 16 Example 17 Top Half of Total 46.5 58.1 23.5 Thickness Bottom Half of 53.5 41.9 76.5 Total Thickness

The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the embodiments of the present disclosure. Thus, it should be understood that although the present disclosure has been specifically disclosed by specific embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those of ordinary skill in the art, and that such modifications and variations are considered to be within the scope of embodiments of the present disclosure.

Additional Embodiments

The following exemplary embodiments are provided, the numbering of which is not to be construed as designating levels of importance:

Embodiment 1 provides an abrasive article comprising:

a non-woven web, comprising

    • a fiber or filament component,
    • a first major surface, and
    • a second major surface, wherein a thickness of the non-woven web is defined from the first major surface to the second major surface;

a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web; and

a heat-activated water-forming inorganic component dispersed through the non-woven web.

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

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

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

Embodiment 5 provides the abrasive article of any one of Embodiments 1-4, wherein the fiber component comprises staple fibers.

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

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

Embodiment 8 provides the abrasive article of any one of Embodiments 5-7, wherein the staple fibers have a linear density in a range of from about 15 denier to about 600 denier.

Embodiment 9 provides the abrasive article of any one of Embodiments 5-8, wherein the staple fibers have a linear density in a range of from about 20 denier to about 100 denier.

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

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

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

Embodiment 13 provides the abrasive article of any one of Embodiments 1-12, wherein the fibers comprise a material chosen from a polyester, a nylon, a polypropylene, an acrylic, a rayon, a cellulose acetate, a polyvinylidene chloride-vinyl chloride copolymer, a vinyl chloride-acrylonitrile copolymer, polyester, and combinations thereof.

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

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

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

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

Embodiment 18 provides the abrasive article of any one of Embodiments 1-17, wherein at least one of the shaped abrasive particles of the plurality of shaped abrasive particles is tetrahedral and comprises four faces joined by six edges terminating at four tips, each one of the four faces contacting three of the four faces.

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

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

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

Embodiment 22 provides the abrasive article of any one of Embodiments 18-21 wherein at least one of the four faces is convex.

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

Embodiment 24 provides the abrasive article of any one of Embodiments 18-23, wherein at least one of the tetrahedral abrasive particles has equally-sized edges.

Embodiment 25 provides the abrasive article of any one of Embodiments 18-24, wherein at least one of the tetrahedral abrasive particles has different-sized edges.

Embodiment 26 provides the abrasive article of any one of Embodiments 1-25, wherein at least one of the shaped abrasive particles of the plurality of shaped abrasive particles comprises a first side and a second side separated by a thickness of the shaped abrasive particle, the first side comprises a first face having a triangular perimeter and the second side comprises a second face having a triangular perimeter, wherein the thickness of the shaped abrasive particle is equal to or smaller than the length of the shortest side-related dimension of the particle.

Embodiment 27 provides the abrasive article of Embodiment 26, further comprising at least one sidewall connecting the first side and the second side.

Embodiment 28 provides the abrasive article of Embodiment 27, wherein the at least one sidewall is a sloping sidewall.

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

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

Embodiment 31 provides the abrasive article of any one of Embodiments 26-29, wherein the first face and the second face are substantially non-parallel to each other.

Embodiment 32 provides the abrasive article of any one of Embodiments 26-31, wherein at least one of the first and the second face are substantially planar.

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

Embodiment 34 provides the abrasive article of any one of Embodiments 1-33, wherein at least one of the shaped abrasive particles comprises at least one shape feature comprising: an opening, a concave surface, a convex surface, a groove, a ridge, a fractured surface, a low roundness factor, or a perimeter comprising one or more corner points having a sharp tip.

Embodiment 35 provides the abrasive article of any one of Embodiments 1-34, wherein a portion of the plurality of shaped abrasive particles independently comprise a tip oriented in a direction substantially parallel to a line passing through the first and second major surfaces.

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

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

Embodiment 38 provides the abrasive article of any one of Embodiments 35-37, wherein the tip is in a range of from about 1 degree to about 20 degrees with respect to the line passing through the first major surface and the second major surface.

Embodiment 39 provides the abrasive article of any one of Embodiments 35-38, wherein the tip is in a range of from about 1 degree to about 15 degrees with respect to the line passing through the first major surface and the second major surface.

Embodiment 40 provides the abrasive article of any one of Embodiments 1-39, wherein a portion of the plurality of shaped abrasive particles independently comprise a face oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces.

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

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

Embodiment 43 provides the abrasive article of any one of Embodiments 40-42, wherein the face is in a range of from about 1 degree to about 20 degrees with respect to the line passing through the first major surface and the second major surface.

Embodiment 44 provides the abrasive article of any one of Embodiments 40-43, wherein the face is in a range of from about 1 degree to about 15 degrees with respect to the line passing through the first major surface and the second major surface.

Embodiment 45 provides the abrasive article of any one of Embodiments 1-44, wherein the shaped abrasive particles are distributed through up to about 100% of the thickness of the non-woven web.

Embodiment 46 provides the abrasive article of any one of Embodiments 1-45, wherein the shaped abrasive particles are distributed throughout the thickness of the non-woven web in a plurality of regions.

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

Embodiment 48 provides the abrasive article of any one of Embodiments 46 or 47, wherein the non-woven web comprises two regions of the shaped abrasive particles through the thickness of the non-woven web.

Embodiment 49 provides the abrasive article of any one of Embodiments 46-48, wherein the non-woven web comprises three regions of the shaped abrasive particles through the thickness of the non-woven web.

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

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

Embodiment 52 provides the abrasive article of any one of Embodiments 1-51, wherein the shaped abrasive particles comprise a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol-gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof.

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

Embodiment 54 provides the abrasive article of any one of Embodiments 1-53, wherein the plurality of shaped abrasive particles are at least one of individual abrasive particles and agglomerates of abrasive particles.

Embodiment 55 provides the abrasive article of any one of Embodiments 1-54, further comprising a plurality of crushed abrasive particles.

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

Embodiment 57 provides the abrasive article of any one of Embodiments 1-56, further comprising a binder dispersed throughout the non-woven web.

Embodiment 58 provides the abrasive article of Embodiment 57, wherein the binder is chosen from a polyurethane resin, a polyurethane-urea resin, an epoxy resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, and combinations thereof.

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

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

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

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

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

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

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

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

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

Embodiment 68 provides the abrasive article of any one of Embodiments 65-67, wherein the metal hydroxide comprises lithium hydroxide, sodium hydroxide, potassium hydroxide, aluminum hydroxide, beryllium hydroxide, cobalt(II) hydroxide, copper(II) hydroxide, curium hydroxide, gold(III) hydroxide, iron(II) hydroxide, mercury(II) hydroxide, nickel(II) hydroxide, tin(II) hydroxide, zinc hydroxide, zirconium(IV) hydroxide, or mixtures thereof.

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

Embodiment 70 provides the abrasive article of any one of Embodiments 65-69, wherein at least some of the metal hydroxide component is modified with an amine, an alkyl, an epoxy, a vinyl, a phenyl, or a mixture thereof.

Embodiment 71 provides the abrasive article of any one of Embodiments 1-70, further comprising a flexible backing in contact with the first major surface or the second major surface.

Embodiment 72 provides the abrasive article of Embodiment 71, wherein the flexible backing comprises a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, a staple fiber, a continuous fiber, a nonwoven, a foam, a screen, a laminate, and combinations thereof.

Embodiment 73 provides an abrasive article comprising:

a non-woven web, comprising:

    • a fiber or filament component;
    • a first major surface;
    • a second major surface, wherein a thickness of the non-woven web is defined therebetween;

a plurality of shaped abrasive particles dispersed through the non-woven web;

an aluminum trihydrate component dispersed through the non-woven web.

Embodiment 74 provides an abrasive article comprising:

a non-woven web, comprising:

    • a fiber or filament component;
    • a first major surface;
    • a second major surface, wherein a thickness of the non-woven web is defined there between;

a plurality of shaped abrasive particles dispersed through the non-woven web;

a hydrated aluminum compound dispersed through the non-woven web,

wherein about 5% to about 70% of the plurality of shaped abrasive particles comprise a tip oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces.

Embodiment 75 provides an abrasive article comprising:

a non-woven web, comprising:

    • a fiber or filament component;
    • a first major surface;
    • a second major surface, wherein a thickness of the non-woven web is defined there between;

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

a hydrated aluminum compound dispersed through the non-woven web, wherein a portion of the plurality of shaped abrasive particles comprising a tip oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces is in a range of from about 5% to about 70% of the plurality of shaped abrasive particles

Embodiment 76 provides a slurry comprising:

a plurality of shaped abrasive particles;

a heat-activated water-forming inorganic component; and

a binder;

a lubricant; and

a solvent.

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

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

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

Embodiment 80 provides the slurry of any one of Embodiments 76-79, wherein the binder is in a range of from about 10 wt % to about 70 wt % of the slurry.

Embodiment 81 provides the slurry of any one of Embodiments 76-80, wherein the binder is chosen from a polyurethane resin, a polyurethane-urea resin, an epoxy resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, and combinations thereof.

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

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

Embodiment 84 provides the slurry of any one of Embodiments 76-83, wherein the heat-activated water-forming inorganic component is an endothermic heat-activated water-forming inorganic component comprising a reaction temperature of about 300° C. or less.

Embodiment 85 provides the slurry of any one of Embodiments 76-84 wherein the heat-activated water-forming inorganic component is an endothermic heat-activated water-forming inorganic component comprising a reaction temperature in a range of from about 200° C. to about 300° C.

Embodiment 86 provides the slurry of any one of Embodiments 76-85, wherein the heat-activated water-forming inorganic component is an endothermic heat-activated water-forming inorganic component comprising a reaction temperature in a range of from about 200° C. to about 250° C.

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

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

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

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

Embodiment 91 provides a method of making the abrasive article of any one of Embodiments 1-90, comprising:

forming a non-woven web of the fibers or filaments;

perforating the web;

applying the abrasive particles and a binder to the perforated web; and

curing the binder, to provide the abrasive article.

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

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

Embodiment 94 provides the method of any one of Embodiments 91-93, wherein the abrasive particles are applied to the non-woven web at an add-on weight ranging from about 100 g/m2 to about 5000 g/m2.

Embodiment 95 provides the method of any one of Embodiments 91-94, wherein the abrasive particles are applied to the non-woven web at an add-on weight ranging from about 2000 g/m2 to about 4000 g/m2.

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

Embodiment 97 provides the method of Embodiment 91-96, wherein the fibers are air laid with a web-forming machine.

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

contacting an abrasive article of any one of Embodiments 1-75, or formed by the method of any one of Embodiments 91-97, against the workpiece; and

moving the abrasive article relative to the workpiece while maintaining pressure between the abrasive article and the workpiece surface to remove material therefrom.

Embodiment 99 provides the method of Embodiment 98, wherein the abrasive article is in the shape of a disc having a center axis and moving the abrasive article relative to the workpiece is accomplished by rotating the abrasive article about the center axis.

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

Embodiment 101 provides the method of any one of Embodiments 98-100, wherein a greater amount of the workpiece is removed than is removed by a corresponding abrasive article run at the same speed and differing only by having less heat-activated water-forming inorganic component or no heat-activated water-forming inorganic component.

Claims

1. An abrasive article comprising:

a non-woven web, comprising: a fiber or filament component, a first major surface, and a second major surface, wherein a thickness of the non-woven web is defined from the first major surface to the second major surface;
a plurality of individual shaped abrasive particles dispersed through at least a portion of the non-woven web; and
a heat-activated water-forming inorganic component dispersed through the non-woven web.

2. The abrasive article of claim 1, wherein the fibers comprise a material chosen from a polyester, a nylon, a polypropylene, an acrylic, a rayon, a cellulose acetate, a polyvinylidene chloride-vinyl chloride copolymer, a vinyl chloride-acrylonitrile copolymer, and combinations thereof.

3. The abrasive article of claim 1, wherein the individual shaped abrasive particles are distributed throughout the thickness of the non-woven web in a plurality of regions.

4. The abrasive article of claim 1, wherein the individual shaped abrasive particles comprise a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol-gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof.

5. The abrasive article of claim 1, wherein the heat-activated water-forming inorganic component is in a range of from about 1 wt % to about 20 wt % of the abrasive article.

6. The abrasive article of claim 1, wherein the heat-activated water-forming inorganic component is an endothermically heat-activated water-forming inorganic component having an activation temperature of about 300° C. or less.

7. The abrasive article of claim 1, wherein the heat-activated water-forming inorganic component comprises a metal hydroxide.

8. The abrasive article of claim 7, wherein the metal hydroxide is a hydrated aluminum compound.

9. An abrasive article comprising:

a non-woven web, comprising: a fiber or filament component; a first major surface; a second major surface, wherein a thickness of the non-woven web is defined therebetween;
a plurality of individual shaped abrasive particles dispersed through the non-woven web; and
a hydrated aluminum compound dispersed through the non-woven web.

10. A method of making the abrasive article of claim 9, comprising:

forming a non-woven web of the fibers or filaments;
perforating the web;
applying the abrasive particles and a binder to the perforated web; and
curing the binder, to provide the abrasive article.

11. The method of claim 10, wherein forming the non-woven web of fibers comprises air-laying the fibers.

12. A method for removing material from the surface of a workpiece, the method comprising:

contacting an abrasive article of claim 9, or formed by the method of any one of claim 10 or 11, against the workpiece; and
moving the abrasive article relative to the workpiece while maintaining pressure between the abrasive article and the workpiece surface to remove material therefrom.

13. The method of claim 12, wherein the abrasive article is in the shape of a disc having a center axis and moving the abrasive article relative to the workpiece is accomplished by rotating the abrasive article about the center axis.

14. The method of claim 12, wherein the material removed from the workpiece is carbon steel.

15. The method of claim 12, wherein a greater amount of the workpiece is removed than is removed by a corresponding abrasive article run at the same speed and differing only by having less heat-activated water-forming inorganic component or no heat-activated water-forming inorganic component.

Patent History
Publication number: 20210379731
Type: Application
Filed: Oct 4, 2019
Publication Date: Dec 9, 2021
Inventors: Jacob S. BEVERIDGE (Stillwater, MN), Joan W. SCHROEDER (Woodbury, MN)
Application Number: 17/250,982
Classifications
International Classification: B24D 11/00 (20060101); B24D 3/34 (20060101); D04H 1/732 (20060101);