Abstract: A fiber can be made having a structure with an axial core and a coating layer. The fiber can have a polymer core and one or two layers surrounding the core. The fine fiber can be made from a polymer material and a resinous aldehyde composition such that the general structure of the fiber has a polymer core surrounded by at least a layer of the resinous aldehyde composition.

Abstract: Abrasive articles including a nonwoven fibrous substrate having a plurality of fibers, and a multiplicity of shaped abrasive particles, each shaped abrasive particle adhered to a corresponding fiber, each shaped abrasive particle having a length (L) and a width (W) determined in a direction substantially orthogonal to the length, the ratio of the length to the width defining an aspect ratio (L/W) of at least 1.1, each abrasive particle is oriented relative to its corresponding fiber, and more than 50% of the abrasive particles are oriented with respect to their corresponding fiber such that the abrasive particle length extends generally outwardly away from a surface of the corresponding fiber as determined visually using the Orientation Test. The shaped abrasive particles may have the geometric shape of a polygonal prism having two faces and at least three sides thereon. Methods of making the abrasive articles are also disclosed.

Abstract: [Problem] To provide a grindstone and a grinding/polishing device using same with which, in addition to it being possible to perform the three processes of rough processing, lapping, and polishing with the same device: double-sided processing is also possible; processing rate does not decrease even when used continuously; and dressing can be omitted. [Solution] A grindstone for grinding/polishing workpieces, the grindstone being characterized in comprising multiple grindstone pillars, which are obtained from a binding agents and abrasive grains for grinding/polishing the workpieces and disposed in parallel with an axis (L) in the depth direction of the grinding/polishing surface, and the grindstone matrix integrally formed with the grindstone pillars, and a grinding/polishing device using said grindstone.

Abstract: A process for forming a moldable, uncured nonwoven composite containing forming a outermost nonwoven layer, forming a structural nonwoven layer, needling the structural nonwoven layer and the outermost nonwoven layer together from both the outer surface of the outermost nonwoven layer and the second surface of the structural nonwoven layer, applying an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C. to the second surface of the structural nonwoven layer, and at least partially drying the uncured, wet nonwoven composite. Heat and pressure may be applied to form the moldable, uncured composite. A moldable, uncured nonwoven composite and a molded, cured nonwoven composite are also disclosed.

Abstract: A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130° C. forming an moldable, uncured composite. The structural nonwoven layer contains a plurality of bi-component binder fibers and a plurality of reinforcing fibers, the bi-component fibers containing a core and a sheath. The core contains a polymer having a melting temperature of at least about 180° C. and the sheath contains a polymer having a melting temperature less than about 180 ° C. A process for forming a molded, cured composite containing forming a structural nonwoven layer and a molded cured nonwoven composite are also disclosed.

Abstract: Composition, apparatus, and methods of composition and apparatus manufacture, for sharpening a paper shredder blade. Composition includes grinding powder, thickening agent, and additive. The thickening agent may be a white oil, an animal oil, an vegetable oil, or a stearine wax. The additive may be an antirust powder, an antiwear powder, an antistatic powder, or an antioxidation powder. The grinding composition is dispensed into a polyethylene film, and sealed to form the grinding apparatus, as a grinding sheet or a grinding packet. A method for forming a grinding sheet includes selecting the constituent materials for a grinding composition; stirring the constituent grinding composition materials; heating the constituent materials to melting; mixing the constituent materials, while melting and intermixing; cooling and packaging the grinding composition to form a grinding sheet or packet.

Abstract: Composition, apparatus, and methods of composition and apparatus manufacture, for sharpening a paper shredder blade. Composition includes grinding powder, thickening agent, and additive. The thickening agent may be a white oil, an animal oil, a vegetable oil, or a stearine wax. The additive may be an antirust powder, an antiwear powder, an antistatic powder, or an antioxidation powder. The grinding composition is dispensed into a polyethylene film, and sealed to form the grinding apparatus, as a grinding sheet or a grinding packet. A method for forming a grinding sheet includes selecting the constituent materials for a grinding composition; stirring the constituent grinding composition materials; heating the constituent materials to melting; mixing the constituent materials, while melting and intermixing; cooling and packaging the grinding composition to form a grinding sheet or packet.

Abstract: Composition, apparatus, and methods of composition and apparatus manufacture, for sharpening a paper shredder blade. Composition includes grinding powder, thickening agent, and additive. The thickening agent may be a white oil, an animal oil, an vegetable oil, or a stearine wax. The additive may be an antirust powder, an antiwear powder, an antistatic powder, or an antioxidation powder. The grinding composition is dispensed into a polyethylene film, and sealed to form the grinding apparatus, as a grinding sheet or a grinding packet. A method for forming a grinding sheet includes selecting the constituent materials for a grinding composition; stirring the constituent grinding composition materials; heating the constituent materials to melting; mixing the constituent materials, while melting and intermixing; cooling and packaging the grinding composition to form a grinding sheet or packet.

Abstract: Composition, apparatus, and methods of composition and apparatus manufacture, for sharpening a paper shredder blade. Composition includes grinding powder, thickening agent, and additive. The thickening agent may be a white oil, an animal oil, an vegetable oil, or a stearine wax. The additive may be an antirust powder, an antiwear powder, an antistatic powder, or an antioxidation powder. The grinding composition is dispensed into a polyethylene film, and sealed to form the grinding apparatus, as a grinding sheet or a grinding packet. A method for forming a grinding sheet includes selecting the constituent materials for a grinding composition; stirring the constituent grinding composition materials; heating the constituent materials to melting; mixing the constituent materials, while melting and intermixing; cooling and packaging the grinding composition to form a grinding sheet or packet.

Abstract: Composition, apparatus, and methods of composition and apparatus manufacture, for sharpening a paper shredder blade. Composition includes grinding powder, thickening agent, and additive. The thickening agent may be a white oil, an animal oil, an vegetable oil, or a stearine wax. The additive may be an antirust powder, an antiwear powder, an antistatic powder, or an antioxidation powder. The grinding composition is dispensed into a polyethylene film, and sealed to form the grinding apparatus, as a grinding sheet or a grinding packet. A method for forming a grinding sheet includes selecting the constituent materials for a grinding composition; stirring the constituent grinding composition materials; heating the constituent materials to melting; mixing the constituent materials, while melting and intermixing; cooling and packaging the grinding composition to form a grinding sheet or packet.

Abstract: Endless abrasive belt useful for polishing or otherwise abrading surfaces.

Abstract: A polishing pad for polishing semiconductors and other planar substrates in the presence of a slurry comprising abrasive particles and a dispersive agent is disclosed. The polishing pad includes a soluble component within a polymer matrix component. The soluble component includes particles soluble in the slurry sufficiently to provide a void structure in the polishing surface of the pad. The void structure enhances the polishing rate and uniformity by increasing the mobility of the abrasive particles while reducing scratching of the polished surface. Additives that further enhance polishing and/or assist in the removal of residues generated during polishing, such as surfactants and removers, are optionally incorporated in the soluble particles or topographically coated on the soluble particles.

Abstract: An abrasive filament, a cloth or non-woven made of the filament and an abrasive device, e.g., sanding disk, incorporating the fabric, cloth or non-woven and methods of producing the same are disclosed. The filament has an outer surface to which plural small size particles of an abrasive material are secured. The filament is formed from a mass of a molten polymer material, e.g., nylon, that has been extruded through a small diameter opening to form a hot elongated filamentary body. The abrasive particles, e.g., grit, are applied as a cloud or spray to the outer surface of the hot elongated filamentary body, whereupon they adhere to that surface and remain permanently secured thereto.

Abstract: A polishing pad for polishing semiconductors and other planar substrates in the presence of a slurry comprising abrasive particles and a dispersive agent is disclosed. The polishing pad includes a soluble component, preferably fibrous, within a polymer matrix component. The fibrous component includes fibers soluble in the slurry sufficiently to provide a void structure in the polishing surface of the pad. The void structure enhances the polishing rate and uniformity by increasing the mobility of the abrasive particles while reducing scratching of the polished surface. Additives that further enhance polishing and/or assist in the removal of residues generated during polishing, such as surfactants and removers, are optionally incorporated in the fibrous substance or topographically coated on the fibrous substance.

Abstract: Surface conditioning articles comprising an organic matrix and water-based organic binders are reported. The water-based organic binders include a first binder and a second binder with abrasive particles dispersed and adhered within the second binder. The first binder comprises a mixture of a phenolic resin and a carboxylated butadiene-acrylonitrile copolymer latex, in the range of weight ratio of dry materials of said latex versus said phenolic resin of 90/10 to 60/40.

Abstract: A canvas abrasive material has a coating of resin and abrasive grains on a woven fabric layer, wherein the crossing places of the yarns form grinding places and free places that are distributed in a grid form over the surface of the abrasive material. A VELCRO-type clinging layer on the abrasive material facilitates manipulation.

Abstract: An abrasive molding predominantly comprised of manganese oxide is described, which has a bulk density of 0.4 to 4.0 g/cm3, a BET specific surface area of 0.2 to 250 m2/g and an average particle diameter of 0.005 to 10 &mgr;m. The abrasive molding has a multiplicity of minute pores, preferably with a pore diameter distribution such that the integrated pore volume of minute pores having a pore diameter of at least 1 &mgr;m is at least 20%, the integrated pore volume of minute pores having a pore diameter of 10 to 100 &mgr;m is at least 15%, and the integrated pore volume of minute pores having a pore diameter exceeding 100 &mgr;m is not larger than 5%, based on the total integrated pore volume of the minute pores of the abrasive molding. The porosity is preferably in the range of 30 to 95% by volume based on the apparent volume of the abrasive molding. The minute pores are preferably interconnecting minute pores which are open to the exterior, wherein a solid is contained which is soluble in a polishing liquid.

Abstract: Described are abrasive articles comprising a nonwoven; a binder layer contacting the nonwoven and at least partially filling spaces between fibers of the nonwoven; first abrasive particles adhered to the binder layer; a slurry layer comprising a second binder and second abrasive particles, the slurry layer contacting the nonwoven and the first layer and at least partially filling spaces within the fibers of the nonwoven; and, methods of preparation of such articles.

Abstract: The present invention provides an improved nonwoven abrasive product. The improved abrasive product has a porous, lofty web of multiple layers of coiled, autogenously bonded thermoplastic filaments, binder resin, abrasive granules and size resin. When porous, lofty web, before adding binder resin, abrasive granules or size resin, has a coil weight in the range of 17 to 28 g/24 in2 (1.097 to 1.808 kg/m2) and is variegated, and the coated porous lofty web exhibits a relatively high measured load/deflection value then the useful life of the abrasive product is greatly increased compared to abrasive products made from webs having lower coil weights and no variegation.

Abstract: This invention describes a method of making abrasive products such as discs with enhanced resistance to deformation as a result of the influence of moisture by laminating a coated abrasive having a fibrous backing lacking dimensional stability when exposed to humidity to a secondary backing comprising an isotropic mat of fibers in a matrix of a polymer.

Abstract: Abrasive articles comprising a cured thermosetting binder and abrasive grains. The binder is prepared with a poly-functional molecule which contains at least two functional groups selected from the group consisting of carboxyl, anhydride and amine, and a (hydroxyalkyl)urea crosslinking agent containing a single urea group, at least two hydroxyl groups, and have at least two carbon atoms disposed between the urea group and each of the hydroxyl groups. The abrasive articles comprise bonded, nonwoven or coated abrasive articles.

Abstract: An abrasive article is provided which includes a peripheral surface formed comprising a grinding aid. The grinding aid is formed from a mixture including an acid and at least one of an inorganic metal phosphate salt or an inorganic metal sulfate salt. The acid is preferably selected so that the mixture forms a film. The abrasive article preferably has sharp abrasive particles. The inventive abrasive article improves grinding efficacy, particularly in titanium grinding processes, as compared to abrasive articles that are substantially devoid of a grinding aid of the present invention. Also provided is a method for making an abrasive article and a method of abrading a surface with an abrasive article.

Abstract: A method for manufacturing a foraminous abrasive article whereby abrasive particles are concentrated in an external surface region of a foraminous substrate. The method includes the steps of: providing a foamable, hardenable, liquid resin composition and a foraminous substrate having an external surface; foaming the resin composition effective to disperse a plurality of gas bubbles throughout the resin composition; applying the foamed resin composition to the external surface of the substrate to form a foam coating layer having an upper surface; applying a plurality of abrasive particles to the upper surface of the foam coating layer; heating the foamed coating layer effective to eliminate the gas bubbles from the foamed coating layer; and hardening the resin composition to attach the abrasive particles to the substrate. The invention also concerns the foraminous abrasive article products of this method.

Abstract: Abrasive slurries, abrasive articles made from the abrasive slurries, and methods for the production of the abrasive articles are disclosed. The abrasive slurries and abrasive articles made therefrom comprise at least two grades of abrasive particles (i.e., a first larger grade, and a second smaller grade). The abrasive grades have a median particle size ratio of about 2, where the median particle size ratio equals the median particle size of the larger grade of abrasive particles divided by the median particle size of any smaller grade of abrasive particles.

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

Abstract: Methods for preparing abrasive articles and novel methods of making abrasive articles are presented. One method includes inserting a fibrous material adjacent an interior surface of a drum. A composition comprising an organic binder precursor material is then placed in the drum, and the drum is rotated such that centrifugal forces distribute the composition, including the organic binder precursor material, uniformly about the fibrous material. The composition is exposed to conditions sufficient to solidify the organic binder precursor material such that an endless, flexible, seamless substrate is formed having an outer surface formed adjacent the interior surface of the drum, an inner surface opposite the outer surface and the fibrous material embedded therein. Coated abrasives formed by this method, as well as other methods, are provided wherein an effective amount of a fibrous reinforcing material is engulfed within an organic polymeric binder material.

Abstract: Coatable compositions suitable for use in producing abrasive articles are presented. The inventive coatable compositions comprise a free radically polymerizable composition, abrasive particles, and a photoinitiator system. The photoinitiator system consists essentially of a compound which cleaves via .alpha.-cleavage and has a molar absorptivity in dilute methanol solution ranging from about 4 to about 400 liter/mole-cm in at least some portion of the UV/visible spectrum ranging from about 395 and about 500 nanometers. Abrasive articles incorporating cured versions of the compositions are presented, as well as methods of making and using the articles.

Abstract: Ceramic abrasive grits are formed by an impregnation process that involves preparing an alumina hydrate sol, drying the sol to form a porous solid, crashing the solid to produce particles, calcining the dried particles, preparing a mixture of an additive metal oxide or its precursor in a liquid vehicle, impregnating the mixture into the calcined particles, drying the impregnated particles, calcining the dried impregnated particles, and firing the particles to produce ceramic abrasive grits. The concentration of the modifying additive metal is greater at or near the surface of the grit than at the interior of the grit.

Abstract: Film-backed and paper-backed coated abrasives and methods of making same are described using coatable urea-aldehyde binder precursor compositions including a urea-aldehyde resin and a cocatalyst, which yield more consistent quality coated abrasives. In addition, the compositions have longer pot life and allow curing at lower temperatures. The urea-aldehyde resins have an aldehyde/urea molar ratio of at least about 1.0, more preferably ranging from about 1.0 to about 2.0, and a free aldehyde content ranging from about 0.1 to about 3.0 weight percent based on weight of total aldehyde. The cocatalyst consists essentially of a Lewis acid and a salt selected from the group consisting of ammonium ion salts and organic amine salts. Paper-backed abrasive articles may employ a fabric nonwoven layer between the abrasive coating and the paper layer to reduce abrasive particle shelling.

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

Abstract: A coated abrasive backing material is provided which is suitable for heavy duty grinding applications is provided by a continuous solid resin matrix having dispersed therein an essentially isotropic fibrous web. The invention also provides a coated abrasive based on said backing.

Abstract: Composite abrasive wheels having shaped abrasive grits bonded to a fibrous substrate are more effective than their counterparts with irregularly shaped grain, especially at finer grit sizes.

Abstract: Abrasive articles are described that include a plurality of abrasive particles, a plurality of coated grinding aid particles, the coated grinding aid particles comprising grinding aid particles coated with an inert, hydrophobic, hydrocarbon-containing substance, and a binder in which the abrasive particles and the coated grinding aid particles are dispersed.

Abstract: Ceramic abrasive grits are formed by an impregnation process that involves preparing an alumina hydrate sol, drying the sol to form a porous solid, crushing the solid to produce particles, calcining the dried particles, preparing a mixture of an additive metal oxide or its precursor in a liquid vehicle, impregnating the mixture into the calcined particles, drying the impregnated particles, calcining the dried impregnated particles, and firing the particles to produce ceramic abrasive grits. The concentration of the modifying additive metal is greater at or near the surface of the grit than at the interior of the grit.

Abstract: An abrasive article and methods for making such abrasive articles, including coated and nonwoven abrasive articles, comprising (a) a plurality of abrasive particles and (b) a bond system which adheres the plurality of abrasive particles together, the bond system comprising a binder; the binder being formed from a binder precursor essentially free of organic solvent, the binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst system and, in particular, a coated abrasive comprising (a) a backing having a major surface, (b) a plurality of abrasive particles, and (c) a bond system which adheres the plurality of abrasive particles to the major surface of the backing, the bond system comprising a binder; the binder being formed from a binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst, wherein the blend comprises from a

Abstract: Abrasive articles that comprise a plurality of abrasive particles, a plurality of erodible agglomerates, and an abrasive binder are described. The erodible agglomerates comprise a plurality of grinding aid particles adhered together by a binder comprising a lignosulfonate.

Abstract: A preferred abrasive grain comprises a sintered product of a precursor material comprising alumina, zirconia, and rare earth oxide. The preferred abrasive grain has an average hardness of at least about 21 GPa and an average toughness of at least about 4 MPa.multidot.m.sup.1/2. A method of preparing preferred abrasive grain is provided. The improved abrasive grain are useful in abrasive products.

Abstract: Surface treating articles having varying degree of smear-resistance and their methods of manufacture are presented. One preferred article is characterized by an organic matrix substantially engulfed by a novel, tough, adherent elastomeric resinous binder system comprising a reaction product of either selected from(1) a polyurethane prepolymer with an amine curative,(2) a polyurethane prepolymer emulsion with an epoxy-functional material and an amine functional material, and(3) a polyurethane polymer emulsion with an epoxy-functional material and an amine-functional material in an aqueous system.

Abstract: An abrasive article comprising a binder and abrasive grits, wherein the abrasive grits comprise abrasive particles having specified shapes. Coated abrasive articles of this invention comprise a backing having at least one layer of abrasive material adhered thereto by means of a binder. A portion of this layer contains abrasive particles having specified shapes. It is preferred that the geometric shape of these abrasive particles be triangular. For triangular-shaped particles, about 35% to about 65% of the particles are oriented with a vertex pointing away from the backing and a base in contact with the binder, with about 35% to about 65% of the particles being oriented with a base pointing away from the backing and a vertex in contact with the binder.

Abstract: An improved fibrous composite structure for use in grinding, cutting and/or polishing operations, normally with abrasives. Webs of fibrous materials, preferably blends of fibers having different deniers are fed to a needling apparatus and are needled, starting with at least two such webs. The needles force fibers from the webs along the path of needle travel and withdraw generally clean, leaving voids that define pores. Further individual layers are needled in like fashion to alternating opposite sides of the structure. Needles pass through an amount greater than fifty percent of the then thickness of the structure adequate to produce a unitary composite, though, and most preferably entirely through the thickness. The process for producing the composite products and embodiments of the products are also disclosed and claimed.

Abstract: A method of producing an abrasive backing or a polishing sheet material which has a nonwoven fabric of a synthetic fiber having a network structure and impregnated with a polyurethane solution. The method has the steps of completely coagulating and drying the polyurethane solution to prepare a base material, removing a skin layer from each surface thereof, dipping the resultant base material in an aqueous solution of a solvent for a short period of time, and treating it in a high-temperature atmosphere for a short period of time.

Abstract: The use of an aromatic amine salt of a substituted pentafluoroantimonic acid as a curing agent for epoxy resins, and the use of the epoxy resin compositions as binders for abrasives in abrasive sheet products, are disclosed. The aromatic amines are selected from aniline and hindered aromatic amines.

Abstract: The present invention provides for the combination of a fibrous carrier which is readily degradable when wet, and foam-forming materials, that produce a protective layer of fibers and foam on the surface of the water contained in a toilet, so as to inhibit splash and noise associated with the deposition of waste into the toilet bowl.

Abstract: A low-density abrasive product formed of a uniform cross-section lofty web comprised of continuous three-dimensionally undulated inter-engaged autogenously bonded filaments of high yield strength filament-forming material impregnated with a tough adherent binder which adherently bonds the filaments together and also bonds a multitude of abrasive granules uniformly dispersed throughout the web. The abrasive article is made by forming the web by an extrusion process, uniformly coating the filaments of the web with a liquid curable binder resin, depositing the abrasive granules onto the web coating, curing the first binder coating, applying a second coating of liquid curable binder and then curing the binder.

Abstract: A soft abrasive tool is disclosed as comprising a solid molded mixture of edetermined quantities of an aluminum wool material and a catalyst setting elastomeric polyurethane binder material, the unique combination of which has been mixed, molded under pressure, and cured at room temperature in such manner as to have a disc-like, cup-like, or other predetermined geometrical configuration. A power source -- such as a motor or the like -- may be used to mechanically drive the aforesaid soft abrasive tool, so that it will cut, grind, and remove polyurethane paint, polysulfide sealant, and other soft coatings from aluminum aircraft skin without damaging the substrate aluminum thereof when held thereagainst.

Abstract: A low-density abrasive article, especially suited for scouring steel griddle surfaces without causing undesirable surface roughness thereto, comprises a lofty, open, fibrous web of curved continuous glass filament bundles which is impregnated with a hard thermoset resin containing abrasive particles.

Abstract: An abrasive article comprising a binder and abrasive grits, wherein the abrasive grits comprise abrasive particles having specified shapes. Coated abrasive articles of this invention comprise a backing having at least one layer of abrasive material adhered thereto by means of a binder. A portion of this layer contains abrasive particles having specified shapes. It is preferred that the geometric shape of these abrasive particles be triangular. For triangular-shaped particles, about 35% to about 65% of the particles are oriented with a vertex pointing away from the backing and a base in contact with the binder, with about 35% to about 65% of the particles being oriented with a base pointing away from the backing and a vertex in contact with the binder.