Nonwoven abrasive articles comprising abrasive particles

Abstract

Various disclosed embodiments relate to nonwoven abrasive articles comprising abrasive particles. In various embodiments, the present invention provides a nonwoven abrasive article comprising a nonwoven web comprising fibers and holes between the fibers. The nonwoven abrasive article comprises abrasive particles, wherein each hole between the fibers independently comprises one or more abrasive particles. Each hole is independently approximately the same size as one or more abrasive particles therein.

Description

[0001] This patent application is a divisional application of the patent application with application number 201780041100.0, application date June 30, 2017, and invention name “Nonwoven abrasive product including abrasive particles”. Background Art

[0002] Nonwoven abrasive articles typically have a nonwoven web (e.g., a bulky open fiber web), abrasive particles, and a binder material (commonly referred to as a "binder") that bonds the fibers within the nonwoven web to each other and secures the abrasive particles to the nonwoven web. Nonwoven abrasive articles typically have abrasive particles distributed through nonwoven fiber web layers bonded together with a binder material that bonds the nonwoven fiber web layers together and also bonds the abrasive particles to the nonwoven fiber web. For example, a one-piece grinding wheel has individual nonwoven fiber web discs arranged in a parallel manner to form a cylinder with a hollow shaft core. Summary of the invention

[0003] In various embodiments, the present invention provides a kind of nonwoven abrasive article comprising a nonwoven web, and this nonwoven web comprises fiber and the hole between fiber.Described nonwoven abrasive article comprises abrasive grain, and each hole between fiber independently comprises one or more abrasive grain.Each hole is independently approximately the same size with one or more abrasive grain therein.

[0004] In various embodiments, the present invention provides a kind of nonwoven abrasive article comprising a nonwoven web, and this nonwoven web comprises fiber and the hole between fiber.The fiber in the nonwoven fiber web comprises the first fiber with the first diameter and the second fiber with the second diameter.The nonwoven abrasive grain comprises abrasive grain, and at least a part in the hole between fiber comprises one or more abrasive grains independently.The denier number of the first fiber is about 3.The denier number of the second fiber is about 15.The first fiber is about 25 weight % of the fiber in the nonwoven web.The second fiber is about 75 weight % of the fiber in the nonwoven web.

[0005] In various embodiments, the present invention provides a kind of nonwoven abrasive product comprising fiber and the hole between fiber.Described nonwoven abrasive product comprises abrasive grains, and wherein at least a portion in the hole between fiber independently comprises one or more abrasive grains.Each hole is independently approximately the same size with one or more abrasive grains therein.For the test wheel with the diameter of 6.0 inches (15.2cm) and width of 0.5 inch (1.27cm) of identical composition with nonwoven abrasive product, when using 8 pounds (3.63kg) of power and under the condition of 3600 revolutions per minute, 15 seconds on and 15 seconds off, on the carbon steel of 1 / 8 inch (0.32cm) diameter, tested 30 minutes, the wear amount of described test wheel is the test wheel of about 2g to about 5g. For a 6.0 inch (15.2 cm) diameter test wheel having the same composition as the nonwoven abrasive article and having a width of 0.5 inch (1.27 cm), when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts from about 30 g to about 50 g of carbon steel. The nonwoven abrasive article has a strength of about 3 g / in 3 About 23g / in 3 density.

[0006] In various embodiments, the present invention provides a method of forming a nonwoven abrasive article. The method includes forming a prebond comprising a resin and fibers. The method includes applying abrasive particles to the prebond. The method includes pressing the coated prebond. The method includes curing the pressed prebond to provide a nonwoven abrasive article.

[0007] In various embodiments, the present invention provides a method of using a nonwoven abrasive article. The method includes abrading a substrate with the nonwoven abrasive article.

[0008] In various embodiments, the nonwoven abrasive article of the present invention has certain advantages over other nonwoven abrasive articles, at least some of which are unexpected. For example, in various embodiments, the nonwoven abrasive article of the present invention can have a wear rate that is superior to other nonwoven abrasive articles. In various embodiments, the nonwoven abrasive article of the present invention can have a cutting rate that is superior to other nonwoven abrasive articles.

[0009] Some nonwoven abrasive articles including abrasive particles such as shaped abrasive particles can have a high cut rate combined with a high wear rate. For example, replacing crushed abrasive particles in a nonwoven abrasive article with shaped abrasive particles can result in an increased cut rate but the same wear rate or an increased wear rate. In various embodiments, the present invention provides a nonwoven abrasive article including abrasive particles such as shaped abrasive particles having a high cut rate combined with a lower wear rate compared to other abrasive articles with similar cut rates. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The drawings show generally by way of example, but not limitation, of the various embodiments discussed in this document.

[0011] Figure 1 is a graph showing wheel specimen wear versus weight % fiber in a wheel prebond according to various embodiments.

[0012] Figure 2 is a graph showing steel cut versus weight % fiber in a wheel pre-bond according to various embodiments.

[0013] Figure 3 Normalized cut versus weight % fiber for various abrasive grains according to various embodiments are shown.

[0014] Figure 4 Normalized wear versus weight % fiber for various abrasive particles according to various embodiments are shown.

[0015] Figure 5 Normalized efficiency versus weight % fiber for various abrasive grains according to various embodiments is shown.

[0016] FIG. 6A to FIG. 6B Micrographs of shaped abrasive particles and various pressed prebonds according to various embodiments are shown. DETAILED DESCRIPTION

[0017] Reference will now be made in detail to certain embodiments of the disclosed subject matter, examples of which are partially illustrated in the accompanying drawings. Although the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplary subject matter is not intended to limit the claims to the disclosed subject matter.

[0018] Throughout this document, values ​​expressed in range format should be interpreted in a flexible manner to include not only the values ​​explicitly listed as range limits, but also all individual values ​​or subranges contained within the range, as if each value and subrange were explicitly listed. For example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted as including not only about 0.1% to about 5%, but also individual values ​​(e.g., 1%, 2%, 3% and 4%) and subranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the range shown. Unless otherwise specified, the statement "about X to Y" has the same meaning as "about X to about Y". Similarly, unless otherwise specified, the statement "about X, Y or about Z" has the same meaning as "about X, about Y or about Z".

[0019] In this document, unless the context clearly dictates otherwise, the terms "a", "an" or "the" are used to include one or more than one. Unless otherwise indicated, the term "or" is used to represent a non-exclusive "or". The statement "at least one of A and B" has the same meaning as "A, B, or A and B". In addition, it should be understood that the words or terms used herein and not otherwise defined are used for descriptive purposes only and not for limitation. Any use of section headings is to assist in reading the document and should not be interpreted as limiting; information related to section headings may appear inside or outside that particular section. All publications, patents, and patent documents mentioned in this document are incorporated herein by reference in their entirety, as if individually incorporated by reference. If there is an inconsistency between the usage of this document and those documents incorporated by reference, the usage in the incorporated reference document should be considered to supplement the usage of this document; for irreconcilable inconsistencies, the usage in this document is subject to.

[0020] In the methods described herein, the actions may be performed in any order without departing from the principles of the invention, except where a temporal or operational order is explicitly recited. In addition, specified actions may be performed simultaneously unless explicit claim language implies that they are to be performed separately.

[0021] For example, an act claimed to do X and an act claimed to do Y may be performed simultaneously within a single operation and the resulting process would fall within the literal scope of the claimed process.

[0022] As used herein, the term "about" can allow a certain degree of variability in values ​​or ranges, for example, within 10%, 5% or 1% of a stated value or a stated range limit, and includes the exact stated value or range.

[0023] As used herein, the term "substantially" means a majority or majority of 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%.

[0024] Nonwoven abrasive products .

[0025] In various embodiments, the present invention provides nonwoven abrasive products. The nonwoven abrasive products include nonwoven webs, and the nonwoven fiber webs include fibers. The nonwoven webs may include holes between the fibers. The nonwoven abrasive products include abrasive particles. In one embodiment, at least a portion of the holes between the fibers may independently include one or more abrasive particles. Each hole may be approximately the same size as one or more abrasive particles therein independently.

[0026] The nonwoven abrasive article may also include a binder. The binder may adhere the abrasive particles to the fibers of the nonwoven web. The binder may be any suitable binder. The binder may be a thermoplastic or thermosetting material. The binder may be a phenolic resin, a polyurethane resin, a leather glue, an acrylic resin, a urea-formaldehyde resin, a melamine-formaldehyde resin, an epoxy resin, or a combination thereof. The polyurethane resin may include a material that is curable to form a poly(urea-urethane), such as a polyurethane having an isocyanate functional group thereon, which may be cured with an amine-containing material.

[0027] The nonwoven abrasive article can include a nonwoven web layer through pressing wherein there is abrasive grain, or can include two or more nonwoven web layers through pressing and bonding wherein there is abrasive grain. For example, the nonwoven abrasive article can include 1 to 20, 1 to 10, 1 or less than, equal to or greater than 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18 or about 20 nonwoven web layers through pressing and bonding wherein there is abrasive grain. The nonwoven abrasive article can be an integrated grinding wheel, which is designed to grind the substrate of the outer periphery of the contact wheel when the wheel rotates around the hole (for example, the mandrel hole) at its center, such as by using a suitable grinder or cutter.

[0028] The nonwoven abrasive article can have any suitable wear rate.In various embodiments, the nonwoven abrasive article can have a lower wear rate than other nonwoven abrasive articles having a similar cut rate. In some embodiments, for a 6.0 inch (15.2 cm) diameter test wheel having the same composition as the nonwoven abrasive article and a 0.5 inch (1.27 cm) width, when tested on 1 / 8 inch diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the wear of the test wheel is from about 1 g to about 20 g of the test wheel, or from about 2 g to about 5 g of the test wheel, or about 1 g or less, or less than, equal to, or greater than about 2 g, 2.5 g, 3 g, 3.5 g, 4 g, 4.5 g, 5 g, 6 g, 7 g, 8 g, 9 g, 10 g, 12 g, 14 g, 16 g, 18 g, or about 20 g or more.

[0029] The nonwoven abrasive article can have any suitable cutting rate. In various embodiments, for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested for 30 minutes on 1 / 8 inch (0.32 cm) diameter carbon steel using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts from about 10 g to about 100 g of carbon steel, or from about 30 g to about 50 g, or from about 35 g to about 45 g, or from about 33 g to about 39 g. , or about 10g or less, or less than, equal to or greater than about 15g, 20g, 22g, 24g, 26g, 28g, 30g, 31g, 32g, 33g, 34g, 35g, 36g, 37g, 38g, 39g, 40g, 41g, 42g, 43g, 44g, 45g, 46g, 47g, 48g, 49g, 50g, 52g, 54g, 56g, 58g, 60g, 65g, 70g, 75g, 80g, 85g, 90g, 95 or about 100g or more.

[0030] The nonwoven abrasive article may have any suitable density, such as a density of at least about 1 g / in 3 To not more than about 23g / in 3 , or at least about 7g / in 3 To not more than about 8g / in 3 , or about 1g / in 3 or less, or less than, equal to, or greater than about 2 g / in 3 、3g / in 3 , 4g / in 3 , 5g / in 3 、6g / in 3、6.2g / in 3 、6.4g / in 3 、6.6g / in 3 、6.8g / in 3 、7g / in 3 、7.1g / in 3 、7.2g / in 3 、7.3g / in 3 、7.4g / in 3 、7.5g / in 3 、7.6g / in 3 、7.7g / in 3 、7.8g / in 3 、7.9g / in 3 、8g / in 3 、8.2g / in 3 、8.4g / in 3 、8.6g / in 3 、8.8g / in 3 , 9g / in 3 、10g / in 3 、11g / in 3 、12g / in 3 、14g / in 3 、16g / in 3 、18g / in 3 、20g / in 3 or 23g / in 3 .

[0031] Abrasive particles .

[0032] The nonwoven abrasive article includes abrasive particles. The abrasive particles can be any suitable abrasive particles. The abrasive particles can be irregularly shaped (e.g., crushed or ground particles) or shaped particles.

[0033] Abrasive grains can be formed by any suitable material. For example, abrasive grains can include materials based on molten aluminum oxide, such as aluminum oxide, ceramic aluminum oxide (which can include one or more metal oxide modifiers and / or crystallization promoters or nucleating agents) and heat-treated aluminum oxide, silicon carbide, co-melted aluminum oxide-zirconium oxide, diamond, cerium dioxide, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, corundum, abrasive grains derived from sol-gel, and mixtures thereof. Abrasive grains can be in the form of, for example, individual particles, agglomerates, composite particles, and mixtures thereof.

[0034] The abrasive particles may be irregularly shaped. For example, the abrasive particles may be obtained by a crushing, grinding or comminution process that produces abrasive particles of random size and shape. The particles may then be screened to give particles having a specific size range.

[0035] The abrasive particles may be shaped abrasive particles. Shaped abrasive particles mean abrasive particles having at least partially repeated shapes. One process for preparing shaped abrasive particles includes forming precursor ceramic abrasive particles in a mold having a predetermined shape to prepare shaped abrasive particles. The shaped abrasive particles formed in the mold are one type of shaped abrasive particles. Other processes for preparing other types of shaped abrasive particles include extruding precursor abrasive particles through an orifice having a predetermined shape, printing precursor shaped abrasive particles through openings in a printing screen having a predetermined shape, or embossing precursor shaped abrasive particles into a predetermined shape or pattern. Non-limiting examples of shaped abrasive particles include set squares, as disclosed in the following patents: U.S. Patents RE 35,570; 5,201,916; 5,984,998; 8,034,137; 8,123,828; 8,142,531; 8,142,532; and 8,142,891; and in U.S. Patent Publications 2009 / 0169816, 2010 / 0146867, and 2010 / 0319269; or elongated ceramic rods / filaments, generally having a circular cross-section, produced by Saint-Gobain Abrasives, examples of which are disclosed in U.S. Patent 5,372,620. The shaped abrasive particles are generally uniform or substantially uniform and retain their sintered shape without the use of a binder, such as an organic or inorganic binder, which can bind smaller abrasive particles into a cohesive structure. The shaped abrasive grain can exclude the particles that can be obtained by crushing, grinding or pulverizing process, and this process produces the abrasive grain of random size and shape.The shaped abrasive grain can have any suitable shape.The shaped abrasive grain can comprise the periphery of polygon and can comprise the side that is generally flat.The shaped abrasive grain can comprise the periphery of triangle (for example, equilateral, isosceles), rectangle, circle, ellipse, trapezoid, pentagon, star or their combination.

[0036] The abrasive particles can have any suitable particle size (e.g., maximum dimension). In various embodiments, the abrasive particles can have a particle size of about 0.01 micron to about 2,000 microns, or about 10 microns to about 750 microns, or about 30 microns to about 150 microns, or about 0.01 micron or less, or less than, equal to, or greater than about 0.1 micron, 1 micron, 2 microns, 3 microns, 4 microns, 5 microns, 6 microns, 8 microns, 10 microns, 12 microns, 14 microns, 16 microns, 18 microns, 20 microns, 25 microns, 30 microns, 35 microns, 40 microns, 45 microns, 50 microns, 55 microns, 60 microns, 65 microns, 70 microns, 75 microns, 80 microns, 85 microns, 90 microns, 96 microns, 97 microns, 98 microns, 100 microns, 101 microns, 102 microns, 103 microns, 104 microns, 105 microns, 106 microns, 107 microns, 108 microns, 109 microns, 110 microns, 111 microns, 112 microns, 113 microns, 114 microns, 115 microns, 116 microns, 117 microns, 118 microns, 119 microns, 120 microns, 121 microns, 122 microns, 123 microns, 124 microns, 125 microns, 126 microns, 127 microns, 128 microns, 129 microns, 130 microns, 131 micro 0 microns, 95 microns, 100 microns, 110 microns, 120 microns, 130 microns, 140 microns, 150 microns, 160 microns, 170 microns, 180 microns, 190 microns, 200 microns, 220 microns, 240 microns, 260 microns, 280 microns, 300 microns, 320 microns, 340 microns, 360 microns, 380 microns, 400 microns, 450 microns, 500 microns, 550 microns, 600 microns, 650 microns, 700 microns, 750 microns, 800 microns, 900 microns, 1,000 microns, 1,500 microns, or about 2,000 microns or greater.

[0037] fiber .

[0038] The nonwoven abrasive article comprises a nonwoven web comprising fibers. The fibers can be made of any suitable material. For example, the fibers can be natural fibers, synthetic fibers, or a mixture of natural fibers and synthetic fibers. Examples of synthetic fibers can include polyester, nylon, polypropylene, acrylonitrile, rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, vinyl chloride-acrylonitrile copolymer, or a combination thereof. Examples of suitable natural fibers include cotton, wool, jute and hemp. The fibers can be natural materials or recycled materials or waste materials recovered, for example, from clothing scraps, carpet manufacturing, fiber manufacturing or textile processing. The fibers can be homogeneous or composite, such as bicomponent fibers (e.g., co-spun sheath-core fibers). The fibers can be continuous filaments, such as those formed by an extrusion process.

[0039] The fiber may have any suitable shape. The fiber may have a circular cross section. In some embodiments, the fiber may have a non-circular cross-sectional shape, or may be a blend of fibers having a circular and non-circular cross-sectional shape. The non-circular cross-sectional shape may include a triangle, a delta shape, an H shape, a trilobal shape, a rectangle, a square, a dog bone shape, a ribbon shape, and an ellipse. The diameter of the fiber with a non-circular cross section is the maximum dimension of the non-circular cross section of the fiber. The fiber may have a generally uniform diameter, wherein the maximum dimension of the cross section of each fiber is generally the same from one end of the fiber to the other end.

[0040] The fibers in the nonwoven web may have a single diameter (eg, a single uniform diameter). The nonwoven web may be substantially free of fibers having diameters that differ from the single diameter. The individual diameters may be from about 0.01 denier (e.g., grams per 9,000 meters) to about 1,000 denier, or from about 3 denier to about 40 denier, or about 0.01 denier or less, or less than, equal to, or greater than about 0.1 denier, 1 denier, 2 denier, 3 denier, 4 denier, 5 denier, 6 denier, 7 denier, 8 denier, 9 denier, 10 denier, 11 denier, 12 denier, 13 denier, 14 denier, 15 denier, 16 denier, 17 denier, 18 denier, 19 denier, 20 denier, 21 denier, 22 denier, 23 denier, 24 denier, 25 denier, 26 denier, 27 denier, 28 denier, 29 denier, 30 denier, 31 denier, 32 denier, 33 denier, 34 denier, denier, 35 denier, 36 denier, 37 denier, 38 denier, 39 denier, 40 denier, 42 denier, 44 denier, 46 denier, 48 denier, 50 denier, 55 denier, 60 denier, 65 denier, 70 denier, 75 denier, 80 denier, 85 denier, 90 denier, 95 denier, 100 denier, 110 denier, 120 denier, 130 denier, 140 denier, 150 denier, 175 denier, 200 denier, 225 denier, 250 denier, 275 denier, 300 denier, 350 denier, 400 denier, 450 denier, 500 denier, 600 denier, 700 denier, 800 denier, 900 denier, or about 1,000 denier or more.

[0041] In some embodiments, the fibers in the nonwoven web may have more than one diameter. For example, the fibers in the nonwoven web may include a first fiber having a first diameter (e.g., a first uniform diameter) and a second fiber having a second diameter (e.g., a second uniform diameter), wherein the first diameter is different from the second diameter. In various embodiments, the fibers in the nonwoven web may include any suitable number of diameters, such as also including a third fiber having a third diameter, a fourth fiber having a fourth diameter, etc.

[0042] In a nonwoven web comprising first fibers and second fibers, the first fibers can form any suitable proportion of fibers in the nonwoven web. For example, the first fibers can be from about 0.001% by weight to about 99.999% by weight of the fibers in the nonwoven web, or from about 10% by weight to about 50% by weight of the fibers in the nonwoven web, or from about 15% by weight to about 40% by weight, or about 0.001% by weight or less, or less than, equal to, or greater than about 0.01%, 0.1%, 1%, 2%, 3%, 4%, 5%, 6%, 8%, 10%, 12%, 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%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 9 %, 26 wt %, 27 wt %, 28 wt %, 29 wt %, 30 wt %, 31 wt %, 32 wt %, 33 wt %, 34 wt %, 35 wt %, 36 wt %, 37 wt %, 38 wt %, 39 wt %, 40 wt %, 42 wt %, 44 wt %, 46 wt %, 48 wt %, 50 wt %, 55 wt %, 60 wt %, 65 wt %, 70 wt %, 75 wt %, 80 wt %, 85 wt %, 90 wt %, 95 wt %, 96 wt %, 97 wt %, 98 wt %, 99 wt %, 99.9 wt %, 99.99 wt %, or about 99.999 wt % or more.The first fiber can be about 0.01 denier to about 1,000 denier, or about 3 denier to about 40 denier, or about 0.01 denier or less, or less than, equal to, or greater than about 0.1 denier, 1 denier, 2 denier, 3 denier, 4 denier, 5 denier, 6 denier, 7 denier, 8 denier, 9 denier, 10 denier, 11 denier, 12 denier, 13 denier, 14 denier, 15 denier, 16 denier, 17 denier, 18 denier, 19 denier, 20 denier, 21 denier, 22 denier, 23 denier, 24 denier, 25 denier, 26 denier, 27 denier, 28 denier, 29 denier, 30 denier, 31 denier, 32 denier, 33 denier, 34 denier, 35 denier, 36 denier, 37 denier, 38 denier, 39 denier, 40 denier, 41 denier, 42 denier, 43 denier, 44 denier, 45 denier, 46 denier, 47 denier, 48 denier, 49 denier, 50 denier, 51 denier, 52 denier, 53 denier, 54 denier, 55 denier, 56 denier, 57 denier, 58 denier, 59 denier, The first fiber may be about 3 denier, 400 denier, 450 denier, 500 denier, 600 denier, 700 denier, 800 denier, 900 denier, or about 1,000 denier or more. The first fiber may be about 3 denier.

[0043] In a nonwoven web comprising first fibers and second fibers, the second fibers can form any suitable proportion of fibers in the nonwoven web. For example, the second fibers can be from about 0.001% to about 99.999% by weight of the fibers in the nonwoven web, or from about 50% to about 90% by weight of the fibers in the nonwoven web, or from about 65% to about 85% by weight, or about 0.001% by weight or less, or less than, equal to, or greater than about 0.01%, 0.1%, 1%, 2%, 4%, 6%, 8%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 52%, 54%, 56%, 58%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 100%, 101%, 102%, 103%, 104%, 105%, 106%, 107%, 108%, 109%, 110%, 111%, 112%, 113%, 114%, 115%, 116%, 117%, 118%, 119%, 120%, 121%, 122%, 123%, 124%, 125 %, 97 wt %, 98 wt %, 99 wt %, 99.9 wt %, 99.99 wt % or about 99.999 wt % or more.The second fiber may be from about 0.01 denier to about 1,000 denier, or from about 3 denier to about 40 denier, or about 0.01 denier or less, or less than, equal to, or greater than about 0.1 denier, 1 denier, 2 denier, 3 denier, 4 denier, 5 denier, 6 denier, 7 denier, 8 denier, 9 denier, 10 denier, 11 denier, 12 denier, 13 denier, 14 denier, 15 denier, 16 denier, 17 denier, 18 denier, 19 denier, 20 denier, 21 denier, 22 denier, 23 denier, 24 denier, 25 denier, 26 denier, 27 denier, 28 denier, 29 denier, 30 denier, 31 denier, 32 denier, 33 denier, 34 denier, 35 denier, 36 denier, 37 denier, 38 denier, 39 denier, 40 denier, 41 denier, 42 denier, 43 denier, 44 denier, 45 denier, 46 denier, 47 denier, 48 denier, 49 denier, 50 denier, 51 denier, 52 denier, 53 denier, 54 denier, 55 denier, 56 denier, 57 denier, 58 denier, 59 denier, The first fiber may be about 15 denier, or about 40 denier. The second fiber may be about 15 denier, or about 40 denier.

[0044] In a nonwoven web comprising a first fiber and a second fiber, the diameter of the first fiber can be smaller than the diameter of the second fiber. For example, the denier of the first fiber can be about 1 denier to about 500 deniers less than the second fiber, or about 5 deniers to about 50 deniers less than the second fiber, or about 1 denier or less, or less than, equal to, or greater than about 2 deniers, 3 deniers, 4 deniers, 5 deniers, 6 deniers, 7 deniers, 8 deniers, 9 deniers, 10 deniers, 11 deniers, 12 deniers, 13 deniers, 14 deniers, 15 deniers, 16 deniers, 17 deniers, 18 deniers, 19 deniers, 20 deniers, 21 deniers, 22 deniers, 23 deniers, 24 deniers, 25 deniers, 26 deniers, 27 deniers, 28 deniers, 29 deniers, 30 deniers, 31 deniers, 32 deniers, 33 deniers, 34 deniers, 35 deniers, 36 deniers, 37 deniers, 38 deniers, 39 deniers, 40 deniers, 41 deniers, 42 deniers, 43 deniers, 44 deniers, 45 deniers, 46 deniers, 47 deniers, 48 ​​deniers, 49 deniers, 50 deniers, 51 deniers, 52 deniers, 53 deniers, 54 deniers, 55 deniers, 56 deniers, 57 deniers, 58 deniers, 59 deniers, 60 deniers, 6 300 denier, 350 denier, 360 denier, 370 denier, 38 denier, 390 denier, 400 denier, 420 denier, 440 denier, 46 denier, 48 denier, 50 denier, 55 denier, 60 denier, 65 denier, 70 denier, 75 denier, 80 denier, 85 denier, 90 denier, 95 denier, 100 denier, 110 denier, 120 denier, 130 denier, 140 denier, 150 denier, 175 denier, 200 denier, 225 denier, 250 denier, 275 denier, 300 denier, 350 denier, 400 denier, 450 denier, or about 500 denier or more.

[0045] In some embodiments, the nonwoven web comprises a first fiber having a diameter of about 3 deniers, which is about 25% by weight of the fibers in the nonwoven web, and a second fiber having a diameter of about 15 deniers, which is about 75% by weight of the fibers in the nonwoven web. In some embodiments, the nonwoven web may be substantially free of fibers other than the first fibers and the second fibers. hole .

[0046] The fiber of nonwoven web comprises hole, and this hole is the space between fiber groups.The fiber that forms hole can be characterized as the cage around hole, and wherein the fiber that forms hole can not isolate hole from surrounding environment.Some or each of the hole between fiber can independently comprise one or more abrasive grains, so that one or more abrasive grains in hole are located in the inside of the cage formed by the fiber that forms hole.Each hole can be approximately the same size with one or more abrasive grains therein independently.In addition to the hole that comprises abrasive grains, nonwoven web can also comprise the hole that does not contain abrasive grains.

[0047] The hole may include one abrasive grain, or more than one abrasive grain. In some embodiments, the hole of a nonwoven abrasive article may include no more than one abrasive grain (e.g., the hole may include zero or one grain). In some embodiments, the hole of a nonwoven abrasive article may include no more than one abrasive grain and may not contain other abrasive grains. In some embodiments, a nonwoven abrasive article may include a secondary hole between fibers. In some embodiments, the secondary hole may be a hole of the same or smaller size as other holes. The secondary hole between fibers may not contain abrasive grains.

[0048] In various embodiments, the one or more abrasive particles in each hole can independently have a volume that is any suitable proportion of the volume of the hole, where the volume of the hole can be considered to be the maximum volume of any shape that does not protrude from the boundary of the hole that the hole can accommodate. The volume of the one or more abrasive particles in each hole can independently be about 50% to about 100% of the hole volume, or about 90% to about 100% of the hole volume, or about 50% or less of the hole volume, or less than, equal to, or greater than about 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99%, 99.9%, 99.99%, or about 99.999%. In various embodiments, the total number of pores in the nonwoven abrasive article that are larger than the abrasive particles by volume may contain one or more abrasive particles in any suitable proportion, such as from about 1% to about 100%, or from about 50% to about 100%, or from about 80% to about 100%, or about 1% or less, or less than, equal to, or greater than about 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 99.9%, 99.99%, or 99.999% or more.

[0049] The hole may be generally conformal to one or more abrasive grains therein. The abrasive grain may include one or more generally flat faces (e.g., the abrasive grain may be a shaped abrasive grain or may be a randomly shaped grain including one or more generally flat faces). The generally flat face of the abrasive grain may contact (e.g., directly contact or be separated by a binder less than 1 fiber diameter thick) one or more fibers of the nonwoven web that are generally parallel to the flat face, such that the contacting fibers are flush and adjacent to the generally flat face. Any suitable proportion of the surface area of ​​the abrasive particles that are substantially planar faces may be contacted by one or more of the parallel fibers (e.g., where the percentages given represent the percentage of the total surface area of ​​all planar faces contacting each particle), such as from about 10% to about 100%, or from about 20% to about 80%, or about 10% or less, or about 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99%, 99.9%, 99.99%, or about 100%.

[0050] Other components .

[0051] The nonwoven abrasive article may include any suitable components.The nonwoven abrasive article may or may not include any of the materials listed in this section.

[0052] The nonwoven abrasive article may include surfactants, emulsifiers, dispersants, crosslinking agents, catalysts, rheology modifiers, density modifiers, cure modifiers, free radical initiators, diluents, antioxidants, thermal stabilizers, flame retardants, plasticizers, fillers, inorganic particles, pigments, dyes, adhesion promoters, antistatic additives, or combinations thereof.

[0053] In some embodiments, the nonwoven abrasive article can include filler particles. For example, the filler particles can be blended with the shaped abrasive particles. Examples of fillers that can be used in the present invention may 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, clay, montmorillonite, feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate), metal sulfates (such as calcium sulfate, barium sulfate, sodium sulfate, sodium aluminum sulfate, aluminum sulfate), gypsum, vermiculite, sugar, wood flour, aluminum trihydrate, 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 (vinyl chloride), polysulfone, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, acetal polymer, polyurethane, nylon particles), and thermosetting particles (such as phenolic bubbles, phenolic beads, polyurethane foam particles, etc.). 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 fluoride, potassium chloride, and magnesium chloride. Examples of metal fillers include tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Other fillers may include sulfur, organic sulfur compounds, graphite, lithium stearate, and metal sulfides.

[0054] Method for making nonwoven abrasive article .

[0055] Various embodiments of the present invention provide methods of making nonwoven abrasive articles. The method can be any suitable method of producing the embodiments of the nonwoven abrasive articles described herein.

[0056] The method may include forming a prebond comprising a resin, fibers, and abrasive particles. The method may include pressing a plurality of prebonds together and then curing the pressed prebonds to form a nonwoven abrasive article.

[0057] In some embodiments, the method may include forming a prebond comprising a resin and fibers. The method may include applying abrasive particles to the prebond. The method may include pressing the prebond. The method may include curing the pressed prebond to provide a nonwoven abrasive article.

[0058] Methods of using nonwoven abrasive articles .

[0059] In one embodiment, the present invention provides a method of using a nonwoven abrasive article. The method can be any suitable method of using an embodiment of a nonwoven abrasive article described herein. The method can include grinding a substrate with an embodiment of a nonwoven abrasive article described herein.

[0060] Example

[0061] Various embodiments of the present invention may be better understood by reference to the following examples which are provided by way of illustration.The present invention is not limited to the examples given herein.

[0062] The materials used in the examples are described in Table 1. Unless otherwise stated, all parts, percentages, ratios, etc. in the examples and the remainder of this specification are by weight. Unless otherwise stated, all other reagents are obtained or purchased from fine chemical suppliers such as Sigma-Aldrich Company, St. Louis, Missouri, or can be synthesized by known methods.

[0063] Table 1: Materials .

[0064]

[0065]

[0066]

[0067] Example 1. Production of an integrated wheel .

[0068] Preparation of prebonds. Nonwoven webs were formed on an airlaid fiber web forming machine purchased from Rando Machine Corporation, Macedon, New York, under the trade designation "RANDO-WEBBER". The fiber webs were formed from the fiber blends shown in Table 4. The web weight was approximately 84 grams per square meter (gsm). The webs were conveyed to a horizontal twin roll coater where a prebond resin was applied at a wet add-on weight of 146 gsm. The prebond resin had the following composition (all percentages relative to component weight): 44.4% water, 28.0% T403S, 18.7% EP1, 0.5% AF, 1% LCD4115, 2.9% T403LiSt, 4.5% CARBEZ3S. The prebond resin was cured to a non-tacky condition by passing the coated web through a convection oven at 345°F (174°C) for 3 minutes to yield a prebonded nonwoven web having a basis weight of 117 gsm.

[0069] A slurry containing precision shaped abrasive particles was prepared, the formulation of which is described in Table 2. A batch of slurries weighing about 13.61 Kg to about 15.88 Kg was prepared using an air-powered high shear mixer, with the speed adjusted to create a strong vortex in the slurry while mixing. The order of component addition is listed in Table 2 in order.

[0070] Table 2: Slurry formulation .

[0071]

[0072] The one-piece grinding wheel is prepared from the pre-bonded nonwoven web as follows. A 10-inch (25 cm) × 12-inch (30 cm) section is cut from the pre-bonded nonwoven web and saturated with abrasive slurry. The saturated pre-bonded web is then passed through the roller gap of a roller coater consisting of a rubber roller with a diameter of 10 inches (25 cm) and a hardness of 85-Shore A durometer to remove excess slurry until the required slurry addition of 1783 gsm is obtained. Typically, the web passes through the roller gap at a speed of 5 feet per minute (1.52 m / min) under a pressure of 10 psi to 25 psi (69 kPa to 172 kPa) to reach the target weight. Four sections of the pre-bonded web are coated with slurry in the above manner. The coated pre-bonded web sections are placed in a blast oven set at 90 ° F (32 ° C) for 5 minutes to remove most of the solvent. To form a single one-piece nonwoven abrasive slab, the four sections are then stacked one on top of the other and placed in a hydraulic heated platen press set at 275°F (135°C). Before placing the release liner in the oven, it is placed on both sides of the stack. The consistent thickness of the one-piece slab is maintained by placing a 0.5 inch (1.27 cm) thick metal shim in each corner of the platen. Pressure (15,000 psi, 103.4 MPa) is applied to the press plate. After 30 minutes, the two sections of the web are fused together to form a single one-piece slab. The slab is placed in a forced air oven set at 275°F (135°C) for 180 minutes. After removal from the oven, the slabs were cooled to room temperature and a 6.0 inch (15.24 cm) diameter, 0.5 inch (1.27 cm) thick one-piece grinding wheel with a 1 inch (2.54 cm) center hole was die-cut from the slabs using a SAMCO SB-25 swing beam press manufactured by Deutsche Vereinigte Schuhmaschinen GmbH & Co., Frankfurt, Germany. The samples prepared are described in Table 3.

[0073] Table 3: Sample wheels prepared in Example 1 .

[0074]

[0075]

[0076] Example 2. Testing of integrated wheels .

[0077] The wear test measured the abrasive efficiency of the comparative test wheel and was performed using a dual-axis automated machine. A 6-inch (15.24 cm) diameter, 0.5-inch (1.27 cm) thick test wheel was mounted on one spindle, and a 2.0-inch (5.08 cm) diameter, 0.125-inch (3.175 mm) thick carbon steel tube workpiece was mounted on the other spindle. The workpiece was set to rotate at a speed of 32 revolutions per minute, and the grinding wheel was set to rotate at a speed of 3,600 revolutions per minute. The grinding wheel and workpiece can be pushed together with a load of 8 pounds (3.63 kg). During the test, the end of the pre-weighed rotating tube was pushed with a pre-weighed wheel at a selected test load for 15 seconds, followed by a non-contact time of 15 seconds. Each wear test was run for a total of 30 minutes, with the total time the workpiece was in contact with the wheel being 15 minutes. The total amount of cutting was determined by the weight loss of the workpiece, and the amount of wheel wear was determined by the weight loss of the grinding wheel. The results are reported as the amount of cut and wear in grams for each test wheel. The grams of cut for the steel and grams of wear for the wheels are shown in Table 4.

[0078] Table 4: Test results .

[0079]

[0080]

[0081] Figure 1 is a graph showing the amount of wear of wheel samples versus weight % 15 denier fibers in a wheel pre-bond for various sizes of abrasive particles. Figure 2 is a graph showing the cut of steel versus weight % FIB1 (weight % in total fiber) for various sizes of abrasive particles. Table 5 gives the normalized values ​​of cut, wear and efficiency (cut divided by wear), where for each different abrasive particle pre-bond containing 100% FIB1, the cut and wear values ​​are normalized to a value of 1, and the cut and wear values ​​for the remaining fiber blends are ratios of the 100% FIB1 cut and wear values. Figure 3 Normalized cut versus wt% FIB1 (wt% in total fibers) is shown. Figure 4 Normalized wear amount versus weight % FIB1 (weight % in total fibers) is shown. Figure 5 Shown are the normalized efficiency versus wt% FIB1.

[0082] Table 5: Normalized test results .

[0083]

[0084]

[0085] Example 3. Comparison of pore size and abrasive particle size .

[0086] Pre-bonds were prepared as described in Example 1 (Preparation of Pre-bonds). They were then pressed between two glass slides to a thickness of 0.125" (0.318 cm). Abrasive particles of size SAP3 were glued to one of the glass slides. Micrographs of each slide were taken at 200X using Keyence. Micrographs are shown in FIG. 6A to FIG. 6B Among them Fig. 6A A fiber having 100 wt.% of FIB1, and Figure 6B Fibers with 25 wt% FIB2 and 75 wt% FIB1. Fig. 6A The pores between the fibers appear larger in the prebond shown, which has 100 wt. % FIB1.

[0087] The terms and expressions that have been adopted are used as terms of description rather than limitation, and it is not intended that such terms and expressions be used to exclude any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications may be made within the scope of the embodiments of the present invention. Therefore, it should be understood that although the present invention has been specifically disclosed through specific embodiments and optional features, modifications and variations of the concepts disclosed herein may be adopted by those of ordinary skill in the art, and such modifications and variations are considered to be within the scope of the embodiments of the present invention.

[0088] Additional Implementation

[0089] The following exemplary embodiments are provided, the numbering of which should not be construed as designating a level of importance:

[0090] Embodiment 1 provides a nonwoven abrasive product, comprising:

[0091] A nonwoven web comprising fibers and pores between the fibers; and

[0092] abrasive particles, each of the holes independently comprising one or more of the abrasive particles;

[0093] Each pore independently has approximately the same size as the one or more abrasive particles therein.

[0094] Embodiment 2 provides a nonwoven abrasive article according to Embodiment 1, wherein the fibers in the nonwoven web have a single diameter.

[0095] Embodiment 3 provides a nonwoven abrasive article according to any one of Embodiments 1 to 2, wherein the fibers in the nonwoven web are from about 0.01 denier to about 1,000 denier.

[0096] Embodiment 4 provides a nonwoven abrasive article according to any one of Embodiments 1 to 3, wherein the fibers in the nonwoven web are from about 3 denier to about 40 denier.

[0097] Embodiment 5 provides a nonwoven abrasive article according to any one of Embodiments 1 to 4, wherein the fibers in the nonwoven web have more than one uniform diameter.

[0098] Embodiment 6 provides a nonwoven abrasive article according to any one of Embodiments 1 to 5, wherein the fibers in the nonwoven web include first fibers having a first diameter and second fibers having a second diameter, the first diameter being different from the second diameter.

[0099] Embodiment 7 provides the nonwoven abrasive article of Embodiment 6, wherein the first fibers are from about 0.001 wt. % to about 99.999 wt. % of the fibers in the nonwoven web.

[0100] Embodiment 8 provides a nonwoven abrasive article according to any one of Embodiments 6 to 7, wherein the first fibers are from about 10 weight percent to about 50 weight percent of the fibers in the nonwoven web.

[0101] Embodiment 9 provides a nonwoven abrasive article according to any one of Embodiments 6 to 8, wherein the first fibers are from about 0.01 denier to about 1,000 denier.

[0102] Embodiment 10 provides a nonwoven abrasive article according to any one of Embodiments 6 to 9, wherein the first fibers are from about 3 denier to about 40 denier.

[0103] Embodiment 11 provides a nonwoven abrasive article according to any one of Embodiments 6 to 10, wherein the second fibers are from about 0.001 wt. % to about 99.999 wt. % of the fibers in the nonwoven web.

[0104] Embodiment 12 provides a nonwoven abrasive article according to any one of Embodiments 6 to 11, wherein the second fibers are from about 50% to about 90% by weight of the fibers in the nonwoven web.

[0105] Embodiment 13 provides a nonwoven abrasive article according to any one of Embodiments 6 to 12, wherein the second fibers are from about 0.01 denier to about 1,000 denier.

[0106] Embodiment 14 provides a nonwoven abrasive article according to any one of Embodiments 6 to 13, wherein the second fibers are from about 3 denier to about 40 denier.

[0107] Embodiment 15 provides a nonwoven abrasive article according to any one of Embodiments 6 to 14, wherein the first fibers have a denier of about 1 denier to about 500 denier less than the second fibers.

[0108] Embodiment 16 provides a nonwoven abrasive article according to any one of Embodiments 6 to 15, wherein the first fibers have a denier that is about 5 denier to about 50 denier less than the second fibers.

[0109] Embodiment 17 provides a nonwoven abrasive article according to any one of Embodiments 6 to 16, wherein the first fibers have a denier of about 3 and the second fibers have a denier of about 15.

[0110] Embodiment 18 provides a nonwoven abrasive article according to any one of Embodiments 6 to 17, wherein the first fibers have a denier of about 3, the second fibers have a denier of about 15, the first fibers are about 25% by weight of the fibers in the nonwoven web, and the second fibers are about 75% by weight of the fibers in the nonwoven web.

[0111] Embodiment 19 provides a nonwoven abrasive article according to any one of Embodiments 1 to 18, wherein each of the pores containing the one or more abrasive particles contains one abrasive particle or contains more than one abrasive particle.

[0112] Embodiment 20 provides a nonwoven abrasive article according to any one of Embodiments 1 to 19, wherein each of the pores containing the one or more abrasive particles contains no more than one abrasive particle.

[0113] Embodiment 21 provides a nonwoven abrasive article according to any one of Embodiments 1 to 20, wherein each of the pores containing the one or more abrasive particles contains one of the abrasive particles and is free of other abrasive particles.

[0114] Embodiment 22 provides a nonwoven abrasive article according to any one of Embodiments 1 to 20, further comprising secondary pores between the fibers that are free of abrasive particles.

[0115] Embodiment 23 provides a nonwoven abrasive article according to any one of Embodiments 1 to 22, wherein the pores are gaps between the fibers.

[0116] Embodiment 24 provides a nonwoven abrasive article according to any one of Embodiments 1 to 23, wherein the volume of the one or more abrasive particles in each pore is independently about 50% to about 100% of the pore volume.

[0117] Embodiment 25 provides a nonwoven abrasive article according to any one of Embodiments 1 to 24, wherein the one or more abrasive particles in each pore independently have a volume, wherein the volume of the one or more abrasive particles in each pore independently ranges from about 90% to about 100% of the pore volume.

[0118] Embodiment 26 provides a nonwoven abrasive article according to any one of Embodiments 1 to 25, wherein the pores are generally conformal to the one or more abrasive particles therein.

[0119] Embodiment 27 A nonwoven abrasive article according to any one of Embodiments 1 to 26, wherein at least a portion of the abrasive particles include one or more substantially planar faces.

[0120] Embodiment 28 provides a nonwoven abrasive article according to Embodiment 27, wherein the generally planar face is in contact with one or more of the fibers of the nonwoven web that are generally parallel to the planar face.

[0121] Embodiment 29 provides a nonwoven abrasive article according to any one of Embodiments 27 to 28, wherein each of the generally planar faces is independently in contact with one or more of the fibers of the nonwoven web that are generally parallel to the corresponding planar face.

[0122] Embodiment 30 provides a nonwoven abrasive article according to any one of Embodiments 1 to 29, wherein the abrasive particles have a particle size of at least about 0.01 microns or at least about 10 microns and have a particle size of not greater than about 750 microns or not greater than about 2,000 microns.

[0123] Embodiment 31 provides a nonwoven abrasive article according to any one of Embodiments 1 to 30, wherein the abrasive particles have a particle size of 30 microns to about 150 microns.

[0124] Embodiment 32 provides a nonwoven abrasive article according to any one of Embodiments 1 to 31, wherein the abrasive particles are shaped abrasive particles.

[0125] Embodiment 33 provides a nonwoven abrasive article according to Embodiment 32, wherein the shaped abrasive particles have a polygonal perimeter.

[0126] Embodiment 34 provides a nonwoven abrasive article according to embodiment 32, wherein the shaped abrasive particles have a perimeter that is triangular, rectangular, circular, elliptical, trapezoidal, pentagonal, or star-shaped.

[0127] Embodiment 35 provides a nonwoven abrasive article according to any one of Embodiments 1 to 34, further comprising a binder that adheres the abrasive particles to the fibers of the nonwoven web.

[0128] Embodiment 36 provides a nonwoven abrasive article according to any one of Embodiments 1 to 35, comprising two or more compression-bonded nonwoven web layers.

[0129] Embodiment 37 provides a nonwoven abrasive article according to any one of Embodiments 1 to 36, wherein the nonwoven abrasive article is a one-piece grinding wheel.

[0130] Embodiment 38 provides a nonwoven abrasive article according to any one of Embodiments 1 to 37, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the wear of the test wheel is from about 1 g to about 20 g of the test wheel.

[0131] Embodiment 39 provides a nonwoven abrasive article according to any one of embodiments 1 to 38, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the wear of the test wheel is from about 2 g to about 5 g of the test wheel.

[0132] Embodiment 40 provides a nonwoven abrasive article according to any one of Embodiments 1 to 39, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts from about 10 g to about 100 g of the carbon steel.

[0133] Embodiment 41 provides a nonwoven abrasive article according to any one of Embodiments 1 to 40, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts from about 30 g to about 50 g of the carbon steel.

[0134] Embodiment 42 provides a nonwoven abrasive article according to any one of Embodiments 1 to 41, wherein the nonwoven abrasive article has a thickness of at least about 1 g / in 3 、3g / in 3 or 7g / in 3 and having a density of not more than about 8 g / in 3 、20g / in 3 or 23g / in 3 density.

[0135] Embodiment 43 provides a nonwoven abrasive article according to any one of Embodiments 1 to 42, wherein the nonwoven abrasive article has a thickness of about 7 g / in 3 About 8g / in 3 density.

[0136] Embodiment 44 provides a method of using the nonwoven abrasive article according to any one of Embodiments 1 to 43, the method comprising:

[0137] A substrate is abraded using the nonwoven abrasive article according to any one of Embodiments 1 to 43.

[0138] Embodiment 45 provides a method for preparing a nonwoven abrasive article according to any one of Embodiments 1 to 44, the method comprising:

[0139] forming a pre-bond comprising a resin and said fibers;

[0140] applying the abrasive particles to the pre-bond;

[0141] pressing the coated pre-bonded member; and

[0142] The pressed prebond is cured to provide a nonwoven abrasive article according to any one of Embodiments 1 to 44.

[0143] Embodiment 46 provides a method according to embodiment 45, the method comprising forming a plurality of pre-bonds, wherein the pressing comprises pressing the plurality of coated pre-bonds together, and wherein the curing comprises curing the plurality of pressed pre-bonds.

[0144] Embodiment 47 provides a nonwoven abrasive article comprising:

[0145] A nonwoven web comprising fibers and pores between the fibers, the fibers in the nonwoven web comprising first fibers having a first diameter and second fibers having a second diameter; and

[0146] abrasive particles, at least a portion of the pores between the fibers independently comprising one or more of the abrasive particles;

[0147] in

[0148] The first fiber has a denier of about 3,

[0149] The second fiber has a denier of about 15,

[0150] The first fibers are about 25% by weight of the fibers in the nonwoven web, and

[0151] The second fibers are about 75% by weight of the fibers in the nonwoven web.

[0152] Embodiment 48 provides a nonwoven abrasive article comprising:

[0153] A nonwoven web comprising fibers and pores between the fibers; and

[0154] abrasive particles, each of the holes between the fibers independently comprising one or more of the abrasive particles;

[0155] in

[0156] Each of the holes is independently approximately the same size as the one or more abrasive particles therein,

[0157] For a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the wear of the test wheel is from about 2 g to about 5 g of the test wheel,

[0158] For a 6.0 inch (15.2 cm) diameter test wheel having the same composition as the nonwoven abrasive article and having a width of 0.5 inch (1.27 cm), when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts from about 30 g to about 50 g of the carbon steel, and

[0159] The nonwoven abrasive article has a thickness of about 3 g / in 3 About 8g / in 3 density.

[0160] Embodiment 49 provides a nonwoven abrasive article or method according to any one or any combination of embodiments 1 to 48, wherein the nonwoven abrasive article or method is optionally configured so that all of the listed elements or options are available for use or selection.

Claims

1. A nonwoven abrasive product comprising: a nonwoven web comprising fibers and pores between the fibers; as well as abrasive particles, each of the pores independently comprising one or more of the abrasive particles, and each pore independently having approximately the same size as the one or more abrasive particles therein, wherein the volume of the one or more abrasive particles in each pore independently is 50% to 100% of the volume of the pore, wherein the fibers in the nonwoven web include first fibers having a first diameter and second fibers having a second diameter, the first diameter being different from the second diameter, wherein the first fibers are 10% to 50% by weight of the fibers in the nonwoven web % by weight, and wherein the second fibers are 50 to 90 wt % of the fibers in the nonwoven web.

2. The nonwoven abrasive article of claim 1, wherein the fibers in the nonwoven web are from 0.01 denier to 1,000 denier.

3. The nonwoven abrasive article of claim 1, wherein the fibers in the nonwoven web are from 3 denier to 40 denier.

4. The nonwoven abrasive article of claim 1, wherein the first fibers are from 0.01 denier to 1,000 denier.

5. The nonwoven abrasive article of claim 1, wherein the first fibers are from 3 denier to 40 denier.

6. The nonwoven abrasive article of claim 1, wherein the second fibers are from 0.01 denier to 1,000 denier.

7. The nonwoven abrasive article of claim 1, wherein the second fibers are from 3 denier to 40 denier.

8. The nonwoven abrasive article of claim 1, wherein the first fibers have a denier that is 1 to 500 denier less than the second fibers.

9. The nonwoven abrasive article of claim 1, wherein the first fibers have a denier that is 5 to 50 denier less than the second fibers.

10. The nonwoven abrasive article of claim 1, wherein the first fibers have a denier of 3 and the second fibers have a denier of 15.

11. The nonwoven abrasive article of claim 1, wherein the first fibers have a denier of 3, the second fibers have a denier of 15, the first fibers are 25% by weight of the fibers in the nonwoven web, and the second fibers are 75% by weight of the fibers in the nonwoven web.

12. The nonwoven abrasive article of claim 1, wherein each of the pores containing the one or more abrasive particles contains one of the abrasive particles and is free of other abrasive particles.

13. The nonwoven abrasive article of claim 1, further comprising secondary pores between the fibers that are free of abrasive particles.

14. The nonwoven abrasive article of claim 1, wherein the pores are interstices between the fibers.

15. The nonwoven abrasive article of claim 1, wherein the volume of the one or more abrasive particles in each pore independently ranges from 55% to 100% of the pore volume.

16. The nonwoven abrasive article of claim 1, wherein the one or more abrasive particles in each pore independently have a volume that is independently 90% to 100% of the pore volume.

17. The nonwoven abrasive article of claim 1, wherein the pores are generally conformal to the one or more abrasive particles therein.

18. The nonwoven abrasive article of claim 1, wherein at least a portion of the abrasive particles include one or more substantially planar faces.

19. The nonwoven abrasive article of claim 18, wherein the generally planar face is in contact with one or more of the fibers of the nonwoven web that are generally parallel to the planar face.

20. The nonwoven abrasive article of claim 19, wherein each of the generally planar faces independently contacts one or more of the fibers of the nonwoven web that are generally parallel to the corresponding planar face.

21. The nonwoven abrasive article of claim 1, wherein the abrasive particles have a particle size of at least 0.01 microns and no greater than 2,000 microns.

22. The nonwoven abrasive article of claim 1, wherein the abrasive particles have a particle size of 30 microns to 150 microns.

23. The nonwoven abrasive article of claim 1, wherein the abrasive particles are shaped abrasive particles.

24. The nonwoven abrasive article of claim 23, wherein the shaped abrasive particles have a polygonal perimeter.

25. The nonwoven abrasive article of claim 23, wherein the shaped abrasive particles have a perimeter that is triangular, rectangular, circular, elliptical, trapezoidal, pentagonal, or star-shaped.

26. The nonwoven abrasive article of claim 1 further comprising a binder adhering the abrasive particles to the fibers of the nonwoven web.

27. The nonwoven abrasive article of claim 1 comprising two or more compression bonded nonwoven web layers.

28. The nonwoven abrasive article of claim 1, wherein the nonwoven abrasive article is a one-piece grinding wheel.

29. The nonwoven abrasive article of claim 1, wherein for a 6.0 inch (15.2 cm) diameter test wheel having the same composition as the nonwoven abrasive article and a 0.5 inch (1.27 cm) width, when tested on 1 / 8 inch diameter carbon steel for 30 minutes using 8 pounds (3.63 kg) of force and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the wear of the test wheel is between 1 g and 20 g of the test wheel.

30. A nonwoven abrasive article according to claim 1, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using 8 pounds (3.63 kg) of force and 3600 revolutions per minute, 15 seconds on and 15 seconds off, the wear of the test wheel is 2 g to 5 g of the test wheel.

31. A nonwoven abrasive article according to claim 1, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using 8 pounds (3.63 kg) of force and 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts 10 g to 100 g of the carbon steel.

32. A nonwoven abrasive article according to claim 1, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts 30 g to 50 g of the carbon steel.

33. The nonwoven abrasive article of claim 1, wherein the nonwoven abrasive article has a thickness of at least 1 g / in 3 And not more than 23g / in 3 density.

34. The nonwoven abrasive article of claim 33, wherein the nonwoven abrasive article has a thickness of at least 3 g / in 3 density.

35. The nonwoven abrasive article of claim 33, wherein the nonwoven abrasive article has a thickness of at least 7 g / in 3 density.

36. The nonwoven abrasive article of claim 33, wherein the nonwoven abrasive article has a thickness of not greater than 20 g / in 3 density.

37. The nonwoven abrasive article of claim 33, wherein the nonwoven abrasive article has a thickness of not greater than 8 g / in 3 density.

38. The nonwoven abrasive article of claim 1, wherein the nonwoven abrasive article has a 3 Up to 8g / in 3 density.

39. The nonwoven abrasive article of claim 21, wherein the abrasive particles have a particle size of at least 10 microns.

40. The nonwoven abrasive article of claim 21, wherein the abrasive particles have a particle size of no greater than 750 microns.

41. A method of using a nonwoven abrasive article according to any one of claims 1 to 40, the method comprising: A substrate is abraded using the nonwoven abrasive article according to any one of claims 1 to 40.

42. A method of preparing a nonwoven abrasive article according to any one of claims 1 to 40, the method comprising: forming a pre-bond comprising a resin and said fibers; applying the abrasive particles to the pre-bond; pressing the coated pre-bonded member; as well as The pressed prebond is cured to provide a nonwoven abrasive article according to any one of claims 1 to 40.

43. The method of claim 42, comprising forming a plurality of pre-bonds, wherein the pressing comprises pressing the plurality of coated pre-bonds together, wherein the curing comprises curing the plurality of pressed pre-bonds.

44. A nonwoven abrasive article comprising: a nonwoven web comprising fibers and pores between the fibers; as well as abrasive particles, each of the pores between the fibers independently containing one or more of the abrasive particles, and each of the pores independently being approximately the same size as the one or more abrasive particles therein, wherein the volume of the one or more abrasive particles in each pore independently is 50% to 100% of the volume of the pore, wherein the fibers in the nonwoven web include first fibers having a first diameter and second fibers having a second diameter, the first diameter being different from the second diameter, wherein the first fibers are 10% to 50% by weight of the fibers in the nonwoven web, and wherein the second fibers are 50% to 90% by weight of the fibers in the nonwoven web, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and at 3600 revolutions per minute, 15 seconds on and 15 seconds off, the wear of the test wheel is 2 g to 5 g, wherein for a test wheel having a diameter of 6.0 inches (15.2 cm) and a width of 0.5 inches (1.27 cm) having the same composition as the nonwoven abrasive article, when tested on 1 / 8 inch (0.32 cm) diameter carbon steel for 30 minutes using a force of 8 pounds (3.63 kg) and conditions of 3600 revolutions per minute, 15 seconds on and 15 seconds off, the test wheel cuts between 30 g and 50 g of the carbon steel, and The nonwoven abrasive article has a 3 Up to 8g / in 3 density.

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