ABLASTIC WITH ENHANCED PERFORMANCE

Description

BACKGROUND

[0001] Non-woven abrasive articles generally have a non-woven web (e.g., a lofty, open, fibrous web), abrasive particles, and a binder material (commonly termed a "binder") that bonds the fibers within the non-woven web to each other and secures the abrasive particles to the non-woven web.

[0002] From DE 10 2011 100725 A1 there is known a bonded abrasive article.SUMMARY OF THE DISCLOSURE

[0003] Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a heat-activated water-forming inorganic component dispersed through the non-woven web.

[0004] Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a hydrated aluminum compound dispersed through the non-woven web.

[0005] Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a hydrated aluminum compound dispersed through the non-woven web. About 5% to about 70% of the plurality of shaped abrasive particles comprise a tip oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces.

[0006] Various embodiments of the present disclosure relate to an abrasive article. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a hydrated aluminum compound dispersed through the non-woven web. A portion of the plurality of shaped abrasive particles comprising a face oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces is in a range of from about 5% to about 70% of the plurality of shaped abrasive particles.

[0007] According to various embodiments of the present disclosure a slurry includes a plurality of shaped abrasive particles. The slurry further includes a heat-activated water-forming inorganic component. The slurry further includes a solvent, lubricant, and a binder.

[0008] According to various embodiments of the present disclosure, a method of making an abrasive article is described. The abrasive article includes a non-woven web. The non-woven web includes a fiber or filament component. The non-woven web further includes a first major surface and a second major surface. A thickness of the non-woven web is defined from the first major surface to the second major surface. The abrasive article further includes a plurality of shaped abrasive particles dispersed through at least a portion of the non-woven web. The abrasive article further includes a heat-activated water-forming inorganic component dispersed through the non-woven web. The method includes forming a non-woven web of the fibers or filaments. The method further includes perforating the web. The method further includes applying the abrasive particles and a binder to the perforated web. The method further includes curing the binder to provide the abrasive article.

[0009] The first major surface, the second major surface, or both may have a substantially non-planar profile.

[0010] The fiber component may be in a range of from about 5 wt% to about 40 wt% of the abrasive article.

[0011] The fiber component may be in a range of from about 10 wt% to about 25 wt% of the abrasive article.

[0012] The fiber component may comprise staple fibers.

[0013] The staple fibers may have a length in a range of from about 35 mm to about 155 mm.

[0014] The staple fibers may have a length in a range of about 40 mm to about 60 mm.

[0015] The staple fibers may have a linear density in a range of from about 15 denier to about 600 denier.

[0016] The staple fibers may have a linear density in a range of from about 20 denier to about 100 denier.

[0017] A crimp index value of the staple fibers may be in a range of from about 25% to about 40%.

[0018] The fibers may be entangled with each other.

[0019] The fibers may be randomly oriented and bonded together at points of mutual contact.

[0020] The fibers may comprise a material chosen from a polyester, a nylon, a polypropylene, an acrylic, a rayon, a cellulose acetate, a polyvinylidene chloride-vinyl chloride copolymer, a vinyl chloride-acrylonitrile copolymer, polyester, and combinations thereof.

[0021] The nylon may be nylon-6,6.

[0022] The abrasive particles may be in a range of from about 2 wt% to about 70 wt% of the abrasive article.

[0023] The abrasive particles may be in a range of from about 5 wt% to about 50 wt% of the abrasive article.

[0024] The shaped abrasive particles may be shaped ceramic abrasive particles.

[0025] At least one of the shaped abrasive particles of the plurality of shaped abrasive particles may be tetrahedral and comprise four faces joined by six edges terminating at four tips, each one of the four faces contacting three of the four faces.

[0026] At least one of the four faces may be substantially planar.

[0027] At least one of the four faces may be concave.

[0028] All of the four faces may be concave.

[0029] At least one of the four faces may be convex.

[0030] All of the four faces may be convex.

[0031] At least one of the tetrahedral abrasive particles may have equally-sized edges.

[0032] At least one of the tetrahedral abrasive particles may have different-sized edges.

[0033] At least one of the shaped abrasive particles of the plurality of shaped abrasive particles may comprise a first side and a second side separated by a thickness of the shaped abrasive particle, the first side comprises a first face having a triangular perimeter and the second side comprises a second face having a triangular perimeter, wherein the thickness of the shaped abrasive particle is equal to or smaller than the length of the shortest side-related dimension of the particle.

[0034] The abrasive article with the first side and second side may further comprise at least one sidewall connecting the first side and the second side.

[0035] The at least one sidewall may be a sloping sidewall.

[0036] A draft angle a of the sloping sidewall may be in a range of from about 95 degrees and about 130 degrees.

[0037] The first face and the second face may be substantially parallel to each other.

[0038] The first face and the second face may be substantially non-parallel to each other.

[0039] At least one of the first and the second face may be substantially planar.

[0040] At least one of the first and the second face may be a non-planar face.

[0041] At least one of the shaped abrasive particles may comprise at least one shape feature comprising: an opening, a concave surface, a convex surface, a groove, a ridge, a fractured surface, a low roundness factor, or a perimeter comprising one or more corner points having a sharp tip.

[0042] A portion of the plurality of shaped abrasive particles may independently comprise a tip oriented in a direction substantially parallel to a line passing through the first and second major surfaces.

[0043] The portion of the plurality of shaped abrasive particles may be in a range of from about 5% to about 70% of the plurality of shaped abrasive particles.

[0044] The portion of the plurality of shaped abrasive particles may be in a range of from about 5% to about 15% of the plurality of shaped abrasive particles.

[0045] The tip may be in a range of from about 1 degree to about 20 degrees with respect to the line passing through the first major surface and the second major surface.

[0046] The tip may be in a range of from about 1 degree to about 15 degrees with respect to the line passing through the first major surface and the second major surface.

[0047] A portion of the plurality of shaped abrasive particles may independently comprise a face oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces.

[0048] The portion of the plurality of shaped abrasive particles may be in a range of from about 5% to about 70% of the plurality of shaped abrasive particles.

[0049] The portion of the plurality of shaped abrasive particles may be in a range of from about 5% to about 15% of the plurality of shaped abrasive particles.

[0050] The face may be in a range of from about 1 degree to about 20 degrees with respect to the line passing through the first major surface and the second major surface.

[0051] The face may be in a range of from about 1 degree to about 15 degrees with respect to the line passing through the first major surface and the second major surface.

[0052] The shaped abrasive particles may be distributed through up to about 100% of the thickness of the non-woven web.

[0053] The shaped abrasive particles may be distributed throughout the thickness of the non- woven web in a plurality of regions.

[0054] The regions may comprise substantially the same wt% of shaped abrasive particles.

[0055] The non-woven web may comprise two regions of the shaped abrasive particles through the thickness of the non-woven web.

[0056] The non-woven web may comprise three regions of the shaped abrasive particles through the thickness of the non-woven web.

[0057] Each of the plurality of regions may extend in a range of from about 10% to about 50% of the thickness of the non-woven web.

[0058] Each of the plurality of regions may extend in a range of from about 33% to about 50% of the thickness of the non-woven web.

[0059] The shaped abrasive particles may comprise a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol- gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof.

[0060] The shaped abrasive particles may be silicon carbide.

[0061] The plurality of shaped abrasive particles may be at least one of individual abrasive particles and agglomerates of abrasive particles.

[0062] The abrasive article may further comprise a plurality of crushed abrasive particles.

[0063] The abrasive article may be a disc.

[0064] The abrasive article may further comprise a binder dispersed throughout the non-woven web.

[0065] The binder may be chosen from a polyurethane resin, a polyurethane-urea resin, an epoxy resin, a urea- formaldehyde resin, a phenol-formaldehyde resin, and combinations thereof.

[0066] The binder may be in a range of from about 10 wt% to about 70 wt% of the abrasive article.

[0067] The heat-activated water-forming inorganic component may be in a range of from about 1 wt% to about 20 wt% of the abrasive article.

[0068] The heat-activated water-forming inorganic component may be in a range of from about 3 wt% to about 10 wt% of the abrasive article.

[0069] The heat-activated water-forming inorganic component may be an endothermically heat- activated water-forming inorganic component having an activation temperature of about 300 °C or less.

[0070] The heat-activated water-forming inorganic component may be an endothermically heat- activated water-forming inorganic component having an activation temperature in a range of from about 200 °C to about 300 °C.

[0071] The heat-activated water-forming inorganic component may be an endothermically heat- activated water-forming inorganic component having an activation temperature in a range of from about 200 °C to about 250 °C.

[0072] The heat-activated water-forming inorganic component may comprise a metal hydroxide.

[0073] The metal may comprise aluminum, beryllium, cobalt, copper, curium, gold, iron, mercury, nickel, tin, gallium, lead, thallium, zinc, zirconium, calcium, potassium, magnesium, lithium, sodium, alloys thereof, or mixtures thereof.

[0074] The metal may in particular be aluminum.

[0075] The heat-activated water-forming inorganic component can include a metal hydroxide. The metal hydroxide may comprise lithium hydroxide, sodium hydroxide, potassium hydroxide, aluminum hydroxide, beryllium hydroxide, cobalt(II) hydroxide, copper(II) hydroxide, curium hydroxide, gold(III) hydroxide, iron(II) hydroxide, mercury(II) hydroxide, nickel(II) hydroxide, tin(II) hydroxide, zinc hydroxide, zirconium(IV) hydroxide, or mixtures thereof.

[0076] The metal hydroxide may be aluminum trihydrate.

[0077] At least some of the metal hydroxide component may be modified with an amine, an alkyl, an epoxy, a vinyl, a phenyl, or a mixture thereof.

[0078] The abrasive article may further comprise a flexible backing in contact with the first major surface or the second major surface.

[0079] The flexible backing may comprise a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, a staple fiber, a continuous fiber, a nonwoven, a foam, a screen, a laminate, and combinations thereof.

[0080] The aluminum trihydrate component may be dispersed through the non-woven web.

[0081] About 5% to about 70% of the plurality of shaped abrasive particles may comprise a tip oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces.

[0082] The shaped abrasive particles may be distributed through the thickness of the non-woven web in a plurality of distributions. A hydrated aluminum compound may be dispersed through the non-woven web. A portion of the plurality of shaped abrasive particles comprises a tip oriented in a direction substantially perpendicular to a line passing through the first and second major surfaces. The portion is in a range of from about 5% to about 70% of the plurality of shaped abrasive particles.

[0083] The disclosure also shows a slurry comprising a plurality of shaped abrasive particles, a heat-activated water-forming inorganic component, a binder, a lubricant, and a solvent.

[0084] The shaped abrasive particles of the slurry may be tetrahedral shaped abrasive particles, triangular shaped abrasive particles, or a mixture thereof.

[0085] The abrasive particles may range from about 2 wt% to about 70 wt% of the slurry.

[0086] The abrasive particles may range from about 5 wt% to about 70 wt% of the slurry.

[0087] The binder may be in a range of from about 10 wt% to about 70 wt% of the slurry.

[0088] The binder of the slurry may be chosen from a polyurethane resin, a polyurethane-urea resin, an epoxy resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, and combinations thereof.

[0089] The heat-activated water-forming inorganic component of the slurry may be in a range of from about 1 wt% to about 20 wt% of the slurry.

[0090] The heat-activated water-forming inorganic component of the slurry may be in a range of from about 3 wt% to about 10 wt% of the slurry.

[0091] The heat-activated water-forming inorganic component of the slurry may be an endothermic heat- activated water-forming inorganic component comprising a reaction temperature of about 300 °C or less.

[0092] The heat-activated water-forming inorganic component of the slurry may be an endothermic heat-activated water-forming inorganic component comprising a reaction temperature in a range of from about 200 °C to about 300 °C.

[0093] The heat-activated water-forming inorganic component of the slurry may be an endothermic heat- activated water-forming inorganic component comprising a reaction temperature in a range of from about 200 °C to about 250 °C.

[0094] The heat-activated water-forming inorganic component of slurry may comprise a hydrated metal.

[0095] The metal of the slurry may comprise aluminum, calcium, potassium, magnesium, alloys thereof, or mixtures thereof.

[0096] The metal may in particular be aluminum.

[0097] The hydrated metal may be a hydrated aluminum compound.

[0098] A further aspect of the present disclosure relates to a method of making the abrasive mentioned above. The method includes the following steps: forming a non-woven web of the fibers or filaments; perforating the web; applying the abrasive particles and a binder to the perforated web; and curing the binder, to provide the abrasive article.

[0099] The abrasive particles may be applied to the first major surface, the second major surface, or both.

[0100] The abrasive particles may be sprayed on the first major surface, the second major surface, or both.

[0101] The abrasive particles may be applied to the non-woven web at an add-on weight ranging from about 100 g / m2 to about 5000 g / m2.

[0102] The abrasive particles may be applied to the non-woven web at an add-on weight ranging from about 2000 g / m2 to about 4000 g / m2.

[0103] Forming the web of fibers may comprise air-laying the fibers.

[0104] The fibers may be air laid with a web-forming machine.

[0105] Further, the disclosure relates to a method for removing material from the surface of a workpiece, the method comprises: contacting an abrasive article as mentioned above, or formed by the method mentioned above, against the workpiece; and moving the abrasive article relative to the workpiece while maintaining pressure between the abrasive article and the workpiece surface to remove material therefrom.

[0106] The abrasive article may be in the shape of a disc having a center axis and moving the abrasive article relative to the workpiece is accomplished by rotating the abrasive article about the center axis.

[0107] The material removed from the workpiece may be carbon steel.

[0108] A greater amount of the workpiece may be removed than is removed by a corresponding abrasive article run at the same speed and differing only by having less heat-activated water forming inorganic component or no heat-activated water-forming inorganic component.BRIEF DESCRIPTION OF THE FIGURES

[0109] The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document. FIG. 1 is a perspective view of an abrasive article. FIG. 2 is a sectional view of the abrasive article of FIG. 1 taken along section line 2-2. FIGs. 3A-3D are schematic diagrams of shaped abrasive particles having a planar trigonal shape, in accordance with various embodiments. FIGs. 4A-4E are schematic diagrams of shaped abrasive particles having a tetrahedral shape, in accordance with various embodiments. FIG. 5 is a graph showing the depth of penetration of shaped abrasive particles in a nonwoven web, in accordance with various embodiments. FIG. 6 is a graph showing the depth of penetration of shaped abrasive particles in a nonwoven web, in accordance with various embodiments. FIG. 7 is a graph showing the depth of penetration of shaped abrasive particles in a nonwoven web, in accordance with various embodiments. DETAILED DESCRIPTION

[0110] Reference will now be made in detail to certain embodiments of the disclosed subject matter, examples of which are illustrated in part in the accompanying drawings. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

[0111] Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement "about X to Y" has the same meaning as "about X to about Y," unless indicated otherwise. Likewise, the statement "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z," unless indicated otherwise.

[0112] In this document, the terms "a," "an," or "the" are used to include one or more than one unless the context clearly dictates otherwise. The term "or" is used to refer to a nonexclusive "or" unless otherwise indicated. The statement "at least one of A and B" has the same meaning as "A, B, or A and B." In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0113] In the methods described herein, the acts can be carried out in any order without departing from the principles of the disclosure, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

[0114] The term "about" as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range.

[0115] The term "substantially" as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

[0116] As used herein "shaped abrasive particle" means an abrasive particle having a predetermined or non-random shape. One process to make a shaped abrasive particle such as a shaped ceramic abrasive particle includes shaping the precursor ceramic abrasive particle in a mold having a predetermined shape to make ceramic shaped abrasive particles. Ceramic shaped abrasive particles, formed in a mold, are one species in the genus of shaped ceramic abrasive particles. Other processes to make other species of shaped ceramic abrasive particles include extruding the precursor ceramic abrasive particle through an orifice having a predetermined shape, printing the precursor ceramic abrasive particle though an opening in a printing screen having a predetermined shape, or embossing the precursor ceramic abrasive particle into a predetermined shape or pattern. In other examples, the shaped ceramic abrasive particles can be cut from a sheet into individual particles. Examples of suitable cutting methods include mechanical cutting, laser cutting, or water-jet cutting. Non-limiting examples of shaped ceramic abrasive particles include shaped abrasive particles, such as triangular plates, or elongated ceramic rods / filaments. Shaped ceramic abrasive particles are generally homogenous or substantially uniform and maintain their sintered shape without the use of a binder such as an organic or inorganic binder that bonds smaller abrasive particles into an agglomerated structure and excludes abrasive particles obtained by a crushing or comminution process that produces abrasive particles of random size and shape. In many embodiments, the shaped ceramic abrasive particles comprise a homogeneous structure of sintered alpha alumina or consist essentially of sintered alpha alumina.

[0117] FIG. 1 is a perspective view of abrasive article 10. FIG. 2 is a sectional view of the abrasive article of FIG. 1 taken along section line 2-2. FIGs. 1 and 2 show substantially the same components and are discussed concurrently. As shown in FIGs. 1 and 2, abrasive article 10 includes non-woven web 12. Non-woven web 12 includes first major surface 14 and opposite second major surface 16. Each of first major surface 14 and second major surface 16 have an irregular or substantially non-planar profile, although in other embodiments either surface may be planar. Non-woven web 12 includes fiber component 18, which includes individual fibers 20. Non-woven web 12 further includes abrasive particles 22, which are dispersed throughout non-woven web 12; binder 24 adheres the abrasive particles to individual fibers 20.

[0118] While not so limited, fiber component 18 can range from about 5 wt% to about 40 wt% of abrasive article 10, about 10 wt% to about 25 wt%, about 10 wt% to about 20 wt%, about 12 wt% to about 15 wt%, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, or 40 wt%. Fiber component 18 can include a plurality of individual fibers 20 that are randomly oriented and entangled with respect to each other. Individual fibers 20 are bonded to each other at points of mutual contact. Individual fibers 20 can be staple fibers or continuous fibers. As generally understood, "staple fiber" refers to a fiber of a discrete length and "continuous fiber" refers to a fiber that can be any suitable fiber or filament such as a synthetic filament, or an inorganic fiber such as a steel filament, a glass fiber, a basalt fiber. The steel can be a stainless steel, a carbon steel, or include metal such as copper or alloys such as brass. Individual fibers 20 can range from about 70 wt% to about 100 wt% of fiber component 18, about 80 wt% to about 90 wt%, less than, equal to, or greater than about 70 wt%, 75, 80, 85, 90, 95, or 100 wt% of fiber component 18. In further embodiments, non-woven web 12 can be free of fiber component 18 or individual fibers 20 and can instead include a sponge or foam material that includes random or ordered cavities.

[0119] The individual staple fibers can have a length ranging from about 35 mm to 155 mm 50 mm to about 105 mm, about 40 mm to about 60 mm, less than, equal to, or greater than about 35 mm, 40, 45, 50, 55, 60, 65, 70, 75, 76, 80, 85, 90, 95, 100, 102, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, or 155 mm. A crimp index value of the individual staple fibers can range from about 15% to about 60%, about 25% to about 50%, less than, equal to, or greater than about 15%, 20, 25, 30, 35, 40, 45, 50, 55, or 60%. Crimp index is a measurement of a produced crimp; e.g., before appreciable crimp is induced in the fiber. The crimp index is expressed as the difference in length of the fiber in an extended state minus the length of the fiber in a relaxed (e.g., shortened) state divided by the length of the fiber in the extended state. The staple fibers can have a fineness or linear density ranging from about 15 denier to about 2000 denier, about 20 denier to about 100 denier, about 500 denier to about 700 denier, about 800 denier to about 1000 denier, about 900 denier to about 1000 denier, less than, equal to, or greater than about 200 denier, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, 2000 denier.

[0120] In some examples, fiber component 18 can include a blend of staple fibers. For example, fiber component 18 can include a first plurality of individual staple fibers and a second plurality of individual staple fibers. The first and second pluralities of staple fibers of the blend can differ with respect to at least one of linear density value, crimp index, or length. For example, a linear density of the individual staple fibers of the first plurality of individual fibers can range from about 15 denier to about 700 denier, about 20 denier to about 100 denier, less than, equal to, or greater than about 200 denier, 250, 300, 350, 400, 450, 500, 550, 600, 650, or about 700 denier. A linear density of the individual staple fibers of the second plurality of individual fibers can range from about 800 denier to about 2000 denier, about 850 denier to about 1000 denier, less than, equal to, or greater than about 800 denier, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, or 2000 denier. Blends of individual staple fibers with differing linear densities can be useful, for example, to provide an abrasive article that upon use can result in a desired surface finish. The length or crimp index of any of the individual fibers can be in accordance with the values discussed herein.

[0121] In examples of the abrasive article including blends of individual staple fibers, the first and second pluralities of individual staple fibers can account for different portions of fiber component 18. For example, a first plurality of individual fibers 20 can range from about 20 wt% to about 80 wt% of fiber component 18, about 30 wt% to about 40 wt%, less than, equal to, or greater than about 20 wt%, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt%. A second plurality of individual fibers 20 can range from about 20 wt% to about 80 wt% of fiber component 18, about 60 wt% to about 70 wt%, less than, equal to, or greater than about 20 wt%, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt%. While two pluralities of individual staple fibers are discussed herein, it is within the scope of this disclosure to include additional pluralities of individual staples fibers such as a third plurality of individual staple fibers that differs with respect to at least one of liner density value, crimp index, and / or length of the first and second pluralities of individual fibers 20.

[0122] Individual fibers 20 of non-woven web 12 can include many suitable materials. Factors influencing the choice of material include whether that material is suitably compatible with adhering binders and abrasive particles 22 while also being processable in combination with other components of abrasive article 10, and the material's ability to withstand processing conditions (e.g., temperatures) such as those employed during application and curing of the binder. The materials of fibers 20 can also be chosen to affect properties of abrasive article 10 such as, for example, flexibility, elasticity, durability or longevity, abrasiveness, and finishing properties. Examples of fibers 20 that may be suitable include natural fibers, synthetic fibers, and mixtures of natural and / or synthetic fibers. Examples of synthetic fibers include those made from polyester (e.g., polyethylene terephthalate), nylon (e.g., nylon-6,6, polycaprolactam), polypropylene, acrylonitrile (e.g., acrylic), rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, polyester (e.g., polyester terephthalate) and vinyl chloride-acrylonitrile copolymer. Examples of suitable natural fibers include cotton, wool, jute, and hemp. Some individual fibers 20 can include an inorganic material a steel, a glass, or a basalt. The steel can be a stainless steel, a carbon steel, or include metal such as copper or alloys such as brass. Individual fibers 20 may be of virgin material or of recycled or waste material, for example, reclaimed from garment cuttings, carpet manufacturing, fiber manufacturing, or textile processing. Individual fibers 20 may be homogenous or a composite such as a bicomponent fiber (e.g., a co-spun sheath-core fiber). Individual fibers 20 can be tensilized and crimped staple fibers.

[0123] In some examples, individual fibers 20 can have a non-circular cross sectional shape or blends of individual fibers 20 having a circular and a non-circular cross sectional shape (e.g., triangular, delta, H-shaped, tri-lobal, rectangular, square, dog bone, ribbon-shaped, or oval).

[0124] Abrasive article 10 includes an abrasive component including shaped abrasive particles 22 adhered to individual fibers 20. Shaped abrasive particles 22 can range from about 5 wt% to about 70 wt% of abrasive article 10, about 40 wt% to about 60 wt%, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70 wt%.

[0125] There are many types of useful abrasive particles 22 that can be included in abrasive article 10 including shaped ceramic abrasive particles and conventional abrasive particles. The abrasive component can include only shaped abrasive particles 22 or conventional abrasive particles. The abrasive component can also include blends of shaped abrasive particles 22 or conventional abrasive particles. For example, the abrasive component can include a blend of about 5 wt% to about 95 w% shaped abrasive particles 22, about 10 wt% to about 50 wt% shaped abrasive particles 22, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 wt% shaped abrasive particles 22 with the balance being conventional abrasive particles. As another example, the abrasive component can include a blend of about 5 wt% to about 95 wt% conventional abrasive particles, about 30 wt% to about 70 wt% conventional abrasive particles, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 wt% conventional abrasive particles with the balance being shaped abrasive particles.

[0126] Shaped abrasive particles 22 can be applied to the fibers as individual abrasive particles (e.g., particles 22 not held together with a binder and applied to fibers 20) or as agglomerates (e.g., particles 22 held together with a binder and applied to fibers 20). Some agglomerates can include particles 22 that are glass bonded or resin bonded. The agglomerates can include crushed abrasive particles, particles 22.

[0127] Shaped abrasive particles 22 include any particle or particles with at least a portion of the abrasive particle having a predetermined shape. The predetermined shape can be replicated, for example, from a mold cavity that is used to form the shaped precursor abrasive particle. In embodiments where shaped abrasive particles 22 are formed in a mold cavity, the predetermined geometric shape may substantially replicate the mold cavity used to form the shaped abrasive particles 22. Shaped abrasive particles 22 may also replicate a shape of a die in examples where a shaped abrasive particle 22 is formed through extrusion. Shaped abrasive particles 22 may also replicate a shape found in a program, for example, a computer-aided-design (CAD) program, if shaped abrasive particles 22 or abrasive article 10 is formed through an additive manufacturing process. Shaped abrasive particles 22 do not refer to randomly sized crushed abrasive particles formed, for example, by a mechanical crushing operation.

[0128] As an example of shaped abrasive particles 22 having a planar trigonal shape, FIGs. 3A-3B show trigonal shaped abrasive particle 22 bounded by trigonal base 30, trigonal top 32, and a plurality of sidewalls 34A, 34B, 34C connecting base 30 and top 32. Base 30 has tips 36A, 36B, 36C having an average radius of curvature of less than 50 micrometers. FIGS. 3C-3D show one face of shaped abrasive particles 22 to better show the radius of curvature for tip 36A. In general, the smaller the radius of curvature, the sharper the sidewall edge will be. In some cases, the base and the top of the shaped abrasive particles are substantially parallel, resulting in prismatic or truncated pyramidal (as shown in FIGS. 3A-3B) shapes, although this is not a requirement. As shown, sidewalls 34A, 34B, and 34C have equal dimensions and form dihedral angles with base 30 of about 82 degrees. However, it will be recognized that other dihedral angles (including 90 degrees) can also be used. For example, the dihedral angle between the base and each of the sidewalls can independently range from 45 to 90 degrees, 70 to 90 degrees, or 75 to 85 degrees.

[0129] FIGs. 4A-4E show examples of shaped abrasive particles 22 having a tetrahedral shape. As shown in FIGs. 4A-4E, tetrahedral shaped abrasive particles 22 are shaped as regular tetrahedrons. As shown in FIG. 4A, tetrahedral shaped abrasive particle 22A has four faces (42A, 44A, 46A, and 48A) joined by six edges (50A, 52A, 54A, 56A, 58A, and 60A) terminating at four tips (62A, 64A, 66A, and 68A). Each of the faces contacts the other three faces at the edges. While a regular tetrahedron (e.g., having six equal edges and four faces) is depicted in FIG. 4A, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22A can be shaped as irregular (e.g., having edges of differing lengths) tetrahedrons.

[0130] Referring now to FIG. 4B, tetrahedral shaped abrasive particle 22B has four faces (42B, 44B, 46B, and 48B) joined by six edges (50B, 52B, 54B, 56B, 58B, and 60B) terminating at four tips (62B, 64B, 66B, and 68B). Each of the faces is concave and contacts the other three faces at respective common edges. While a particle with tetrahedral symmetry (e.g., four rotational axes of threefold symmetry and six reflective planes of symmetry) is depicted in FIG. 4B, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22B can have one, two, or three concave faces with the remainder being planar.

[0131] Referring now to FIG. 4C, tetrahedral shaped abrasive particle 22C has four faces (42C, 44C, 46C, and 48C) joined by six edges (50C, 52C, 54C, 56C, 58C, and 60C) terminating at four tips (62C, 64C, 66C, and 68C). Each of the faces is convex and contacts the other three faces at respective common edges. While a particle with tetrahedral symmetry is depicted in FIG. 4C, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22C can have one, two, or three convex faces with the remainder being planar or concave.

[0132] Referring now to FIG. 4D, tetrahedral shaped abrasive particle 22D has four faces (42D, 44D, 46D, and 48D) joined by six edges (50D, 52D, 54D, 56D, 58D, and 60D) terminating at four tips (62D, 64D, 66D, and 68D). While a particle with tetrahedral symmetry is depicted in FIG. 4D, it will be recognized that other shapes are also permissible. For example, tetrahedral shaped abrasive particles 22D can have one, two, or three convex faces with the remainder being planar.

[0133] Deviations from the depictions in FIGs. 4A-4D can be present. An example of such a tetrahedral shaped abrasive particle 22E is depicted in FIG. 4E, showing tetrahedral shaped abrasive particle 22E that has four faces (40E, 44E, 46E, and 48E) joined by six edges (50E, 52E, 54E, 56E, 58E, and 60E) terminating at four tips (62E, 64E, 66E, and 68E). Each of the faces contacts the other three faces at respective common edges. Each of the faces, edges, and tips has an irregular shape.

[0134] Any of shaped abrasive particles 22 can include any number of shape features. The shape features can help to improve the cutting performance of any of shaped abrasive particles 22. Examples of suitable shape features include an opening, a concave surface, a convex surface, a groove, a ridge, a fractured surface, a low roundness factor, or a perimeter comprising one or more corner points having a sharp tip. Individual shaped abrasive particles can include any one or more of these features.

[0135] Shaped abrasive particles 22 can be oriented on individual fibers 20 in any suitable manner. Shaped abrasive particles 22 can be oriented through application of a magnetic field. Alternatively, shaped abrasive particles 22 can be oriented by placing them into a mold or screen where individual cavities are arranged in a predetermined pattern. The amount of shaped abrasive particles 22 that are oriented can be controlled. For example, at least a portion of the total number of shaped abrasive particles 22 can be oriented such that a tip is oriented in a direction substantially parallel to a line passing through first and second major surfaces 14 and 16. The individual tips can be perfectly aligned with the line passing through first and second major surfaces 14 and 16, but the tip can also be within about 1 degree to about 20 degrees off of perfect alignment, about 1 degree to about 15 degrees, less than, equal to, or greater than about 1 degree, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or about 20 degrees.

[0136] The total amount of shaped abrasive particles 22 having a respective tip oriented in a direction substantially parallel to a line passing through first and second major surfaces 14 and 16 can be in a range of from about 5% to about 70% of the plurality of shaped abrasive particles, about 5% to about 15%, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or about 70%.

[0137] Shaped abrasive particles 22 can be further oriented on individual fibers 20 such that at least a portion of the total number of shaped abrasive particles 22 include a face that is oriented in a direction substantially perpendicular to a line passing through first and second major surfaces 14 and 16. Additionally, in some embodiments, shaped abrasive particles 22 be disposed in a gap between two of more individual fibers 20 and held in place by a resin in contact with one or more fibers 20. The individual faces can be perfectly perpendicular with the line passing through first and second major surfaces 14 and 16, but the face can also be within about 1 degree to about 20 degrees off of perfect alignment, about 1 degree to about 15 degrees, less than, equal to, or greater than about 1 degree, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or about 20 degrees.

[0138] The total amount of shaped abrasive particles 22 having a respective face oriented in a direction substantially perpendicular to a line passing through first and second major surfaces 14 and 16 can be in a range of from about 5% to about 70% of the plurality of shaped abrasive particles, about 5% to about 15%, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or about 70%.

[0139] Shaped abrasive particles 22 can be distributed throughout the thickness of abrasive article 10. The thickness of abrasive article 10 is defined from first major surface 14 and second major surface 16. In embodiments in which any one or both of first major surface 14 and second major surface 16 have a non-planar or irregular surface, the thickness is measured from the maximum distance between first major surface 14 and second major surface 16. Shaped abrasive particles 22 that are not located at first major surface 14 can be located anywhere from a range of about 5% to about 100% of a thickness of fibrous web 102, about 20% to about 80%, or less than, equal to, or greater than about 5%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or about 100%. The portion of shaped abrasive particles 22 that are not located at first major surface 14 can be in a range of from about 10 wt% to about 100 wt% of shaped abrasive particles 22, about 50 wt% to about 100 wt%, or less than, equal to, or greater than about 10 wt%, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or about 100 wt%.

[0140] Shaped abrasive particles 22 can be distributed throughout the thickness of abrasive article 10 homogenously or heterogeneously. Surprisingly, including a heat-activated water-forming inorganic component can help to provide control of where shaped abrasive particles 22 are located in non-woven web 12 and can help to substantially decluster shaped abrasive particles 22 to assist in orienting the particles. In embodiments of abrasive article 10 in which shaped abrasive particles 22 are distributed heterogeneously, shaped abrasive particles 22 can be distributed in a plurality of regions. Each region can account for a percentage of the thickness of abrasive article 10. For example, each region can account for 1% to about 50% of the total thickness of abrasive article 10, about 10% to about 33%, less than, equal to, or greater than about 1%, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or about 50%. Each region can include any suitable wt% of shaped abrasive particles 22. For example, each region can include from about 5 wt% to about 80 wt% of shaped abrasive particles 22, about 33 wt% to about 50 wt%, less than, equal to, or greater than about 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, or about 80 wt%. Each region can include the same wt% of shaped abrasive particles 22. Alternatively, each region can independently have a different wt% of shaped abrasive particles 22. Abrasive article 10 can include any plural number of regions. For example, abrasive article 10 can include 2, 3, 4, or 5 regions.

[0141] Abrasive article 10 can also include conventional (e.g., crushed) abrasive particles. Examples of useful conventional abrasive particles include any abrasive particles known in the abrasive art. Examples of useful abrasive particles include fused aluminum oxide-based materials such as aluminum oxide, ceramic aluminum oxide (which can include one or more metal oxide modifiers and / or seeding or nucleating agents), and heat-treated aluminum oxide, silicon carbide, co-fused alumina-zirconia, diamond, ceria, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, emery, sol-gel derived abrasive particles, and mixtures thereof.

[0142] The conventional abrasive particles can, for example, have an average diameter ranging from about 10 µm to about 2000 µm, about 20 µm to about 1300 µm, about 50 µm to about 1000 µm, less than, equal to, or greater than about 10 µm, 20, 30, 40, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1650, 1700, 1750, 1800, 1850, 1900, 1950, or 2000 µm. For example, the conventional abrasive particles can have an abrasives industry-specified nominal grade. Such abrasives industry-accepted grading standards include those known as the American National Standards Institute, Inc. (ANSI) standards, Federation of European Producers of Abrasive Products (FEPA) standards, and Japanese Industrial Standard (HS) standards. Exemplary ANSI grade designations (e.g., specified nominal grades) include: ANSI 12 (1842 µm), ANSI 16 (1320 µm), ANSI 20 (905 µm), ANSI 24 (728 µm), ANSI 36 (530 µm), ANSI 40 (420 µm), ANSI 50 (351 µm), ANSI 60 (264 µm), ANSI 80 (195 µm), ANSI 100 (141 µm), ANSI 120 (116 µm), ANSI 150 (93 µm), ANSI 180 (78 µm), ANSI 220 (66 µm), ANSI 240 (53 µm), ANSI 280 (44 µm), ANSI 320 (46 µm), ANSI 360 (30 µm), ANSI 400 (24 µm), and ANSI 600 (16 µm). Exemplary FEPA grade designations include P12 (1746 µm), P16 (1320 µm), P20 (984 µm), P24 (728 µm), P30 (630 µm), P36 (530 µm), P40 (420 µm), P50 (326 µm), P60 (264 µm), P80 (195 µm), P100 (156 µm), P120 (127 µm), P120 (127 µm), P150 (97 µm), P180 (78 µm), P220 (66 µm), P240 (60 µm), P280 (53 µm), P320 (46 µm), P360 (41 µm), P400 (36 µm), P500 (30 µm), P600 (26 µm), and P800 (22 µm). An approximate average particles size of reach grade is listed in parenthesis following each grade designation.

[0143] Shaped abrasive particles 22 or crushed abrasive particles can include any suitable material or mixture of materials. For example, shaped abrasive particles 22 can include a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol-gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof. In some embodiments, shaped abrasive particles 22 and crushed abrasive particles can include the same materials. In further embodiments, shaped abrasive particles 22 and crushed abrasive particles can include different materials.

[0144] Filler particles can also be included in abrasive article 10. Examples of useful fillers include metal carbonates (such as calcium carbonate, calcium magnesium carbonate, sodium carbonate, magnesium carbonate), silica (such as quartz, glass beads, glass bubbles and glass fibers), silicates (such as talc, clays, montmorillonite, feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate), metal sulfates (such as calcium sulfate, barium sulfate, sodium sulfate, aluminum sodium sulfate, aluminum sulfate), gypsum, vermiculite, sugar, wood flour, a hydrated aluminum compound, carbon black, metal oxides (such as calcium oxide, aluminum oxide, tin oxide, titanium dioxide), metal sulfites (such as calcium sulfite), thermoplastic particles (such as polycarbonate, polyetherimide, polyester, polyethylene, poly(vinylchloride), polysulfone, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, acetal polymers, polyurethanes, nylon particles) and thermosetting particles (such as phenolic bubbles, phenolic beads, polyurethane foam particles and the like). The filler may also be a salt such as a halide salt. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, magnesium chloride. Examples of metal fillers include, tin, lead, bismuth, cobalt, antimony, cadmium, iron and titanium. Other miscellaneous fillers include sulfur, organic sulfur compounds, graphite, lithium stearate and metallic sulfides. In some embodiments, individual shaped abrasive particles 22 or individual crushed abrasive particles can be at least partially coated with an amorphous, ceramic, or organic coating. Examples of suitable components of the coatings include, a silane, glass, iron oxide, aluminum oxide, or combinations thereof. Coatings such as these can aid in processability and bonding of the particles to a resin of a binder.

[0145] Abrasive article 10 can further include a heat-activated water-forming inorganic component. The heat-activated water-forming inorganic component can be dispersed throughout non-woven web 12. The heat-activated water-forming inorganic component can be in a range of from about 1 wt% to about 20 wt% of the abrasive article 10, about 3 wt% to about 10 wt%, less than, equal to, or greater than about 1 wt%, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, or about 20 wt%. Endothermically heat-activated water-forming inorganic components can be characterized by their ability to dehydrate (e.g., release water) upon exposure to an elevated temperature. The release of water can serve to cool abrasive article 10 during use.

[0146] The elevated temperature can correspond to an activation temperature of the heat-activated water-forming inorganic component. The activation temperature can be about 300 °C or less, about 250 °C or less, about 200 °C or less, about 100 °C or less, in a range of from about 200 °C to about 300 °C, about 200 °C to about 250 °C, less than, equal to, or greater than about 50 °C, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150 ,160, 170, 180, 190, or about 200 °C.

[0147] The heat-activated water-forming inorganic component can include any suitable material or mixture of materials. For example, the heat-activated water-forming inorganic component can include a metal hydroxide. The metal of the metal hydroxide can include aluminum, beryllium, cobalt, copper, curium, gold, iron, mercury, nickel, tin, gallium, lead, thallium, zinc, zirconium, calcium, potassium, magnesium, lithium, sodium, alloys thereof, or mixtures thereof. Specific examples of metal hydroxides include lithium hydroxide, sodium hydroxide, potassium hydroxide, aluminum hydroxide, beryllium hydroxide, cobalt(II) hydroxide, copper(II) hydroxide, curium hydroxide, gold(III) hydroxide, iron(II) hydroxide, mercury(II) hydroxide, nickel(II) hydroxide, tin(II) hydroxide, zinc hydroxide, zirconium(IV) hydroxide, or mixtures thereof. An example of a specific aluminum hydroxide is a hydrated aluminum compound.

[0148] Any of the metal hydroxides can be surface modified. For example, any metal hydroxide can be surface modified with an amine, an alkyl, an epoxy, a vinyl, a phenyl, or a mixture thereof. Any of these groups can be grafted on to the metal hydroxide. These groups can be in a range of from about 1 wt% to about 20 wt% of the metal hydroxide, about 5 wt% to about 10 wt%, less than, equal to, or greater than about 1 wt%, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or about 20 wt% of the metal hydroxide.

[0149] It was surprisingly found that including a heat-activated water-forming inorganic component such as a hydrated aluminum compound with shaped abrasive particles 22, improves grinding performance in abrasive articles. For example, abrasive articles including a hydrated aluminum compound were found to increase grinding performance in abrasive articles used to abrade carbon steel. Additionally, it was surprisingly found that abrasive articles that included a hydrated aluminum compound had a higher percentage of shaped abrasive particles 22 having a tip oriented in an upright position (e.g., substantially parallel to a line extending through first major surface 12 and second major surface 14) than a corresponding abrasive article differing only by being free of aluminum hydrate. Additionally, it was surprisingly found that abrasive articles that included a hydrated aluminum compound had shaped abrasive particles 22 that were able to penetrate the abrasive article 10 to a deeper percentage of the thickness of the abrasive article 10 than a corresponding abrasive article differing only by being free of aluminum hydrate. Additionally, it was surprisingly found that abrasive articles that included a hydrated aluminum compound had shaped abrasive particles that were evenly distributed through the abrasive article 10. It was further surprisingly found that included the hydrated aluminum compound alone or with crushed abrasive particles did not produce abrasive articles that performed as well as those including shaped abrasive particles 22 and the hydrated aluminum compound.

[0150] In some embodiments, abrasive article 10 can include a flexible backing in contact with first major surface 12 or second major surface 14. A flexible backing can be used to impart strength to the abrasive article 10. A flexible backing can also be used to affix a logo or other visual media to the abrasive article 10. Examples of suitable flexible backings include a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, a staple fiber, a continuous fiber, a non-woven, a foam, a screen, a laminate, and combinations thereof.

[0151] Abrasive article 10 can be made by forming a non-woven web and applying adhesive to fiber component 18. A make coat can be applied to non-woven web 12. Non-woven web 12 can be rolled to substantially lay at least some fibers 20 flat that protrude from web 12. Abrasive particles 22 can be applied to the make coat to form the non-woven abrasive web 12. The make coat is cured and an optional size coat may be applied over the make coat, which is subsequently cured to form the abrasive article 10.

[0152] In some embodiments, a scrim or reinforcing layer can be attached to nonwoven abrasive web 12. The scrim can include any suitable material such a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, a vulcanized fiber, a nonwoven, a foam, a screen, a laminate, or combinations thereof. The scrim can be attached to nonwoven web 12 by needle tacking, needle punching, or through a binder.

[0153] The non-woven web 12 can be manufactured, for example, by conventional air laid, carded, stitch bonded, spun bonded, wet laid, and / or melt blown procedures. Air laid non-woven webs can be prepared using a web-forming machine such as, for example, that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, N.Y. The web can also be perforated. In some examples, perforating the web can include needle-punching the web.

[0154] A non-woven abrasive web is prepared by adhering abrasive particles 22 to non-woven web 12 with a curable second binder. Binders useful for adhering abrasive particles 22 to non-woven web 12 can be selected according to the final product requirements. Examples of binders include those comprising polyurethane resin, phenolic resin, acrylate resin, and blends of phenolic resin, urea formaldehyde, latex, epoxy novolac, epoxy resin, and acrylate resin. The coating weight for abrasive particles 22 can depend, for example, on the particular binder used, the process for applying abrasive particles 22 (e.g., spraying), and the size of the abrasive particles 22. For example, the coating weight of abrasive particles 22 on non-woven web 12 can be 100 grams per square meter (g / m 2< ) to about 5000 g / m 2< , about 1500 g / m 2< to about 5000 g / m 2< about 2000 g / m 2< to about 4000 g / m 2< , less than, equal to, or greater than about 100 g / m 2< , 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600, 3700, 3800, 3900, 4000, 4100, 4200, 4300, 4400, 4500, 4600, 4700, 4800, 4900, or 5000 g / m 2< . Abrasive particles 12 can be coated on either or both of the first and second major surfaces of non-woven web 12. Abrasive particles 22 can be coated to achieve a substantially uniform distribution of shaped abrasive particles 22 throughout the web 12.

[0155] Additionally, components such as the heat-activated water-forming inorganic components can be contacted with non-woven web 12. In some embodiments, certain components of abrasive article 10 can be included in a slurry. For example, a slurry can include shaped abrasive particles 22, the heat-activated water-forming inorganic component, the materials of the make coat and the size coat, crushed abrasive particles or any other component or sub-combination of components. The slurry can be stored and applied directly to non-woven web 12.

[0156] Abrasive article 10 can be used to remove a material from a surface of a workpiece. This can be accomplished by contacting a surface of abrasive article 10 against the workpiece. The workpiece can be contacted, for example, at a force ranging from about 1 newton to about 40 newtons. Abrasive article 10 can then be moved (e.g., rotated) relative to the workpiece, while maintaining a pressure between abrasive article 10 and the workpiece surface. While abrasive article 10 can have many suitable shapes, an example of a suitable shape is a disc. Abrasive article 10 can be adapted to remove many different types of materials. Examples of such materials include carbon steel, stainless steel, aluminum, or a polymeric material such as a polymeric surface coating on the workpiece.

[0157] It was surprisingly found that a greater amount of the workpiece was removed than is removed by a corresponding abrasive article run at the same speed and differing only by having less heat-activated water-forming inorganic component or no heat-activated water-forming inorganic component. It was further surprisingly found that abrasive articles including heat-activated water-forming inorganic components were particularly effective in abrading carbon steel.Examples

[0158] Objects and benefits of this disclosure are further illustrated by the following non-limiting examples. Particular materials and amounts thereof recited in these examples, however, as well as other conditions and details, should not be construed to unduly limit this disclosure.

[0159] The following unit abbreviations are used to describe the examples: °C:degrees Centigradecm:centimeterg / m 2< :grams per square meterinch:1 inch = 2.54 centimetermm:millimeter

[0160] Unless stated otherwise, all reagents were obtained or are available from chemical vendors such as Sigma-Aldrich Company, St. Louis, Missouri, or may be synthesized by known methods. Unless otherwise reported, all ratios and percentages are by weight.

[0161] In the Examples that follow, the materials are referred to as follows: AbbreviationDescriptionF1Nylon 6,6 58 denier x 53.3 mm staple fibers, obtained as FIBER 12 from 3M CompanySCR16x16 nylon 840d warp and weft scrim from Highland Industries, Kernersville, NCPU1blocked urethane prepolymer, obtained as "ADIPRENE BL16" from Chemtura Corporation, Middlebury, ConnecticutCURaromatic amine curative, obtained as "RAC-9907" from Royce international, East Rutherford, New JerseyPMApropylene glycol monomethyl ether, obtained as "DOWANOL PMA" from Dow Chemical Company, Midland, MichiganPME1-methoxy 2-propanol obtained as "DOWANOL PM Glycol Ether" from Dow Chemical Company, Midland, MichiganPF1Phenolic resin 80 0701A from Arclin, Ontario, CanadaCCcalcium carbonate, obtained as "HUBERCARB Q325" from Huber Engineered Materials, Quincy, IllinoisLiStlithium stearate, obtained as "LIC 17" from Baerlocher USA, Cincinnati, OhioASIL2amorphous silica, obtained as "CAB-O-SIL M-5" from Cabot Corporation, Cambridge, MassachusettsCBcarbon black, obtained as "RAVEN 16 POWDER" from Columbian Chemicals Corporation, Marietta, GeorgiaPLoligameric diamine, Versalink P650 obtained from Air Products, Allentown, PALUBhydrocarbon distillate as Ace-Lube 23N from LubeTech, St Paul, MNMIN1aluminum oxide, obtained as "ALODUR BFRPL, GRADE 150" from Treibacher Schleif mittel GmbH, Villach, AustriaMIN2aluminum oxide, obtained as "ALODUR BFRPL, GRADE 180" from Treibacher Schleif mittel GmbH, Villach, AustriaPSGShaped abrasive particles were prepared according to the disclosure of U.S. Patent 8,142,531 (Adefris et al.). The shaped abrasive particles were prepared by molding alumina sol gel in equilateral triangle-shaped polypropylene mold cavities. After drying and firing, the resulting shaped abrasive particles were about 0.26 mm (side length) × 0.06 mm thick, with a draft angle of approximately 98 degrees.CUB1Grade 150 crushed ceramic grain, obtained as Cubitron ™< 321 from 3M Company, St Paul, MNATH1aluminum trihydrate (Al(OH) 3 ), obtained as Martinal 107 IO from Huber Engineered Materials, Atlanta, GeorgiaATH2aluminum trihydrate (Al(OH) 3 ), obtained as SB432 from Huber Engineered Materials, Atlanta, GeorgiaATH3aluminum trihydrate (Al(OH) 3 ), obtained as Hymod ®< SB432 SG from Huber Engineered Materials, Atlanta, GeorgiaATH4aluminum trihydrate (Al(OH) 3 ), obtained as Hymod ®< SB432 SH from Huber Engineered Materials, Atlanta, GeorgiaATH5aluminum trihydrate (Al(OH) 3 ), obtained as Hymod ®< 9400 from Huber Engineered Materials, Atlanta, GeorgiaATH6aluminum trihydrate (Al(OH) 3 ), obtained as Hymod ®< 9400 SF from Huber Engineered Materials, Atlanta, GeorgiaATH7aluminum trihydrate (Al(OH) 3 ), obtained as Hymod ®< 9400 SP from Huber Engineered Materials, Atlanta, GeorgiaATH8aluminum trihydrate (Al(OH) 3 ), obtained as Hymod ®< 9400 SG from Huber Engineered Materials, Atlanta, GeorgiaATH9aluminum trihydrate (Al(OH) 3 ), obtained as AH255 from RJ Marshall, Southfield, MI.ATH10aluminum trihydrate (Al(OH) 3 ), obtained as A208 from RJ Marshall, Southfield, MI.ATH11aluminum trihydrate (Al(OH) 3 ), obtained as MX100 from RJ Marshall, Southfield, MI.MDH1Magnesium dihydroxide (Mg(OH) 2 ), obtained as Vertex 100 from Huber Engineered Materials, Atlanta, GeorgiaMDH2Magnesium dihydroxide (Mg(OH) 2 ), obtained as Vertex 100 SA from Huber Engineered Materials, Atlanta, GeorgiaBoehmiteAlO(OH), obtained as Disperal from Sasol, Johannesburg, South AfricaAluminaAl 2 O 3 , obtained as calcined alumina from Almatis, Leetsdale, PAPAFpotassium aluminum fluoride, obtained as potassium aluminum fluoride from KBM Affilips B.V., NetherlandsKBF 4 potassium boron fluoride, obtained as Potassium Fluoroborate Spec 101 from AWSM Industries, a Division of Royale Pigments & Chemicals Inc., Paramus, NJK 2 B 10 O 16 potassium borate decahydrate, obtained as borax decahydrate from U.S. Borax Inc., Greenwood Village, COWCamine functionalized wollostonite, obtained as calcium silicate 10014 silane from Nyco Minerals, Willsboro, New York GRINDING PERFORMANCE Example 1

[0162] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven. Table 1: Table 1: Compositions of Examples 1-9Example 1Example 2Example 3Example 4-9MaterialPrebond CoatingSlurry CoatPME-17.6%16.5%17.6%14.9%PU148.9%----CUR7.6%----PMA20.6%----CaCO 3 19.2%----LiSt1.9%----PF1-21.5%20.1%21.5%20.5%GEO-----CB1.9%--ASIL2-0.3%0.3%0.3%0.3%MINI-28.2%26.4%25.3%24.2%MIN2-28.2%26.4%25.3%24.2%PSG--5.6%5.4%FIL--6.2%6.3%PL-2.3%2.2%2.3%2.2%LUB-2.0%1.9%2.0%1.9% Example 2

[0163] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven.Example 3

[0164] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven.Example 4

[0165] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Example 5

[0166] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of PAF was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Example 6

[0167] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of WC was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Example 7

[0168] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of CC was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Example 8

[0169] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of KBF 4 was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Example 9

[0170] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 1 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of K 2 B 10 O 16 was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven. Table 2: Compositions of Examples 10-14Example 10Example 11Example 12 - 14MaterialPrebond CoatingSlurry CoatPME-17.6%14.9%14.9%PU148.9%---CUR7.6%---PMA20.6%---CaCO319.2%---LiSt1.9%---PF1-21.5%20.5%20.5%GEO----CB1.9%-ASIL2-0.3%0.3%0.3%MIN1-25.3%24.2%24.2%MIN2-25.3%24.2%24.2%PSG---5.4%CUB1-5.65.4%Fill--6.3%6.3%PL-2.3%2.2%2.2%LUB-2.0%1.9%1.9% Example 10

[0171] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 2 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven.Example 11

[0172] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 2 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and CUB1 having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven.Example 12

[0173] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of alumina was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Example 13

[0174] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of boehmite was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Example 14

[0175] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 1 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles having the composition set forth in Table 2 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of MDH1 was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. The abrasive-coated web was then cured in an oven.Test Methods Off Hand

[0176] 3" diameter discs were fitted with Roloc ™< attachment. A carbon steel test panel as well as an aluminum test panel were abraded with a coated abrasive belt corresponding to any of Examples 1-12 on backstand to impose a linear grain on the test piece. The average Ra is 75 µin on carbon steel and 150 µin on aluminum test panels. The panel and disc are then weighed before testing.Off Hand Short Test

[0177] For one minute, working in the direction of the grain of the respective panel, scratches were removed from half of the panel with the nonwoven disc according to any one of Examples 1-12. For a second one-minute period, working in the direction of the grain, the scratches were removed from the second half of the panel. The disc and workpiece were then cleaned and weighed. The Ra of the panel was also measured in 5 discreet areas and recorded.Off Hand Long Test

[0178] For one minute, working in the direction of the grain of the respective panels, scratches were removed from half of the panel with the nonwoven disc according to any one of Examples 1-12. For a second one-minute period, working in the direction of the grain, the scratches were removed from the second half of the panel.

[0179] The panel was weighed before and after the 2-minute period to determine the mass loss of the panel.

[0180] A new panel was used for another 2 minutes with the methodology used above.

[0181] This process was continued for 4 panels - 8 minutes of total off hand grinding time for each disc. The surface finish was measured on the first panel and the fourth panel in 5 discreet areas per panel. The highest and lowest surface finish numbers were discarded and the middle 3 Ra numbers were averaged. The average surface finish from panel 1 and panel 4 were averaged to give the final surface finish number recorded below.XY Auto Test

[0182] 3" diameter discs were fitted with Roloc ™< attachment. The XY tested the disc for 8 cycles. Each cycle was 1 minute long in which the disc abraded a flat test panel. During the testing a robotic arm moved in the X and Y directions abrading the surface of the panel. The Ra that the disc left behind was checked after the first cycle and after cycle #8 in 5 discreet areas. The panel and disc were weighed before cycle 1 and after cycle 8 to determine the substrate and disc mass loss.

[0183] Force and RPM used when abrading carbon steel was either 2.7kg (5lbs) and 9000 RPM or 4.5kg (101bs) and 11,000 RPM.

[0184] Force used when abrading aluminum was either 2.7kg (5lbs) and 9,000 RPM or 2.7kg (5lbs) and 11,0000 RPM. Table 3: Results for tests run on carbon steel substrateXY AutoOff Hand ShortOff Hand LongExampleNormalized CutCut % Increase% WearSurface Finish Ra (uin)Cut (g)Cut % Increase% WearSurface Finish Ra (uin)Cut (g)Cut % Increase% WearSurface Finish Ra (uin)11.00-3.311.01.00-2.615.813.404.514.721.066%4.09.01.011%2.815.113.30-1%3.514.630.99-1%3.115.00.91-9%1.614.713.702%5.713.641.4747%3.116.01.2929%2.818.620.5053%5.117.950.70-30%1.812.00.86-14%1.616.013.20-1%5.214.560.99-1%30.517.50.90-10%0.916.7----70.83-17%33.318.70.90-10%0.917.2----80.70-30%2.414.20.85-15%2.218.00.89-11%8.416.090.45-55%2.212.30.67-33%2.317.00.70-30%11.016.0100.89-11%3.014.70.88-12%3.712.4----111.1414%3.015.20.86-14%3.411.4----120.71-29%2.015.90.79-21%2.621.70.90-10%8.121.0130.90-10%2.315.21.1010%2.415.31.000%6.915.0140.68-32%2.015.00.84-16%2.516.01.011%5.915.7 Table 4: Results for tests run on aluminum substrate XY AutoOff Hand ShortExampleNormalized CutCut % Increase% WearSurface Finish Ra (uin)Cut (g)Cut % Increase% WearSurface Finish Ra (uin)11.00-31.333.11.00-11.252.020.99-1%30.132.00.95-0.0514.453.531.066%28.039.50.95-0.059.654.841.2121%32.441.11.030.0311.259.551.055%30.635.61.020.0211.044.361.099%36.148.91.080.0811.349.771.000%35.956.51.030.0311.345.781.1111%30.539.51.100.1013.054.090.86-14%34.629.91.070.0713.859.0100.98-2%28.631.30.90-0.1013.534.8110.93-7%30.029.60.94-0.0614.133.8120.97-3%28.235.2----131.000%27.731.5----141.000%29.234.2---- ABRASIVE ARTICLE CONSTRUCTION

[0185] Table 5: Compositions of Examples 15-17Example 15Example 16Example 17MaterialPrebond CoatingSlurry CoatPME-17.6%16.5%14.4%PU148.9%---CUR7.6%---PMA20.6%---CaCO319.2%---LiSt1.9%---PF1-21.5%20.1%17.6%GEO----CB1.9%---PIG1---ASIL2-0.3%0.3%0.3%MIN1-25.3%23.7%20.8%MIN2-25.3%23.7%20.8%PSG-5.6%5.3%4.6%Fill-6.2%17.6%PL-2.3%2.2%1.9%LUB-2.0%1.9%1.6% Example 15

[0186] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 5 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition set forth in Table 5 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. The abrasive-coated web was then cured in an oven.Example 16

[0187] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 5 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition set forth in Table 5 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 6.2 wt% to the slurry spray. The abrasive-coated web was then cured in an oven.Example 17

[0188] A lofty, random air-laid web, having F1 Fibers at a weight of ~314 g / m 2< , was formed using equipment such as that available under the trade designation "RANDO WEBBER" commercially available from Rando Machine Company of Macedon, New York. The web was further needle-punched to a flexible backing, SCR, in a needle loom, rolled, and a prebond coating having the composition set forth in Table 5 was applied to the air-laid fabric to achieve a dry add-on weight of 355 g / m 2< . The prebond was then cured in an oven. A slurry coat containing abrasive particles BFRPL1, BFRPL2, and PSG having the composition set forth in Table 5 was applied at a dry add-on weight of 1252.9 g / m 2< to the pre-bonded air-laid web. FIL in the form of ATH1 was added at 17.6 wt% to the slurry spray. The abrasive-coated web was then cured in an oven. Table 6: Results for Tests Run on Carbon SteelXY AutoOff Hand ShortExampleNormalized CutCut % Increase% WearSurface Finish Ra (uin)Normalized CutCut % Increase% WearSurface Finish Ra (uin)151.00-3.114.51.00-2.616.6161.45453.220.01.32323.817.0171.97973.716.71.52524.119.0 Table 7: Results for Tests Run on Aluminum XY AutoOff Hand ShortExampleNormalized CutCut % Increase% WearSurface Finish Ra (uin)Normalized CutCut % Increase% WearSurface Finish Ra (uin)151.00-24.235.61.00-11.642.6161.161625.544.81.05510.153.7171.242425.147.51.16168.960.7 Test Methods PSG Orientation

[0189] Orientation diagrams for the PSG particle were generated for Examples 15, 16, and 17. The orientation diagrams use the directional cosines of the short / minimum axis (PSG width) and the long / maximum axis (PSG length). The Y component of the minimum axis versus the Z component of the maximum axis of each PSG were plotted. Each point in the diagram is an individual PSG object (i.e., single PSG, PSG cluster, PSG + crushed cluster) and N = # is shown for each plot, where N is the number of PSG objects measured in the scanned dataset. The coordinates (0,0) on the diagram refer to a PSG object with a perfectly upright orientation (preferred orientation). The coordinates (90,90) or (-90,-90) refer to a PSG object with a flat orientation (non-preferred orientation). The values between 0 and 90 on the Max Z axis indicate the angle of the directional cosine with respect to a vector normal to the sample scrim / plane. From the plots, it was possible to determine the % of particles in an upright position (PSG with angle <15° from the normal sample plane) and to determine the % of grains in a flat orientation.PSG Penetration

[0190] X-ray microtomography analysis was used to determine the depth of penetration of PSGs in the nonwoven webs. To carry out the procedure, a strip of material was cut from each abrasive article of Examples 15, 16, and 17. Each Example was scanned using a Skyscan 2211 (Bruker microCT, Kontich, Belgium) X-ray microtomography scanner at a resolution of 6.00 um. Data were collected using X-ray source settings of 70 kV and 110 uA with the energy distribution of the incident beam modified by application of a 0.5 mm aluminum filter. Projected images were recorded at discrete sample rotation angles using a flat panel detector as the sample was rotated through a 360 degree angular range using a 0.10 degree angular step size. Five individual detector frames were averaged per collected projected image. Reconstruction was conducted using computer program NRecon (v 1.6.10, Bruker microCT, Kontich, Belgium) where corrections for X-ray source centering, detector ring artifacts, and beam hardening were employed.

[0191] The resulting reconstructed images were subjected to post processing to isolate the location of shaped grains within the scanned specimen. A greyscale threshold permitted isolation of abrasive grain from higher and lower density material in the nonwoven construction. Computer program CT Analyzer (v 1.16.4, Bruker microCT, Kontich, Belgium) was used for initial processing of the reconstructed datasets.

[0192] Subsequent size filtering on the thresholded images removed small non-shaped abrasive grains from the images. The thresholded and size-filtered images were analyzed to determine the size, shape, and location (centroid coordinates at X, Y, and Z) of the shaped abrasive grains within the dataset volume. The thresholded and size-filtered images were then saved as a separate dataset for subsequent examination of shaped grain orientation. Computer software Avizo (v 9.5.0, ThermoFisher Scientific, Hillsboro, Oregon) was used for further processing of the reconstructed data as well as for shaped grain analysis.

[0193] The physical location of each shaped abrasive grain in the dataset was identified and the short and long axis of each shaped grain were evaluated. The direction cosines for the normals to the short and long axis were calculated and tabulated.

[0194] The thresholded images were subjected to re-slicing along the XZ plane to obtain depth profile images of the dataset using CT Analyzer. The area of the abrasive grains was determined for each depth profile image using Avizo.Results

[0195] Results from the orientation analysis are shown in Table 8. Table 8: Orientation of PSGExample% PSG in Upright Orientation% PSG in Flat Orientation1510.06.1168.05.61711.64.2

[0196] FIGs. 5-7 show that PSG particles were distributed through the total depth of the nonwoven webs. Moreover, PSGs were be distributed within a plurality of regions. That is, there was a region or regions having a higher concentration of PSGs along the depth of the nonwoven web. Representative regions had substantially the same concentration of PSGs or each region or had different concentrations. Table 9 shows the concentration of PSG in Examples 15-17 across the total thickness of the abrasive article, specifically Table 9 shows the wt% of particles in a region accounting for the top third of the total thickness; a region accounting for the middle third of the total thickness; and a region accounting for the bottom third of the total thickness. Table 10 shows the wt% of particles in a region accounting for the top half of the total thickness and a region accounting for the bottom half of the total thickness. Table 9Wt% PSG of Example 15Wt% PSG of Example 16Wt% PSG of Example 17Top Third of Total Thickness34.840.913.7Middle Third of Total Thickness30.620.619.5Bottom Third of Total Thickness36.539.068.4 Table 10 Wt% PSG of Example 15Wt% PSG of Example 16Wt% PSG of Example 17Top Half of Total Thickness46.558.123.5Bottom Half of Total Thickness53.541.976.5

[0197] The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the embodiments of the present disclosure.

Claims

1. A nonwoven abrasive article (10) comprising: a non-woven web (12), comprising a lofty, open fibrous web having: a fiber or filament component (18), a first major surface (14), and a second major surface (16), wherein a thickness of the non-woven web (12) is defined from the first major surface (14) to the second major surface (16); a plurality of individual shaped abrasive particles (22) dispersed through at least a portion of the non-woven web (12); and a heat-activated water-forming inorganic component dispersed through the non-woven web (12).

2. The abrasive article (10) of claim 1, wherein the fibers (18) comprise a material chosen from a polyester, a nylon, a polypropylene, an acrylic, a rayon, a cellulose acetate, a polyvinylidene chloride-vinyl chloride copolymer, a vinyl chloride-acrylonitrile copolymer, and combinations thereof.

3. The abrasive article (10) of any one of claims 1 or 2, wherein the individual shaped abrasive particles (22) are distributed throughout the thickness of the non-woven web (12) in a plurality of regions.

4. The abrasive article (10) of any one of claims 1-3, wherein the individual shaped abrasive particles (22) comprise a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol-gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof.

5. The abrasive article (10) of any one of claims 1-4, wherein the heat-activated water-forming inorganic component is in a range of from about 1 wt% to about 20 wt% of the abrasive article (10).

6. The abrasive article (10) of any one of claims 1-5, wherein the heat-activated water-forming inorganic component is an endothermically heat-activated water-forming inorganic component having an activation temperature of about 300 °C or less.

7. The abrasive article (10) of any one of claims 1-6, wherein the heat-activated water-forming inorganic component comprises a metal hydroxide.

8. The abrasive article (10) of claim 7, wherein the metal hydroxide is a hydrated aluminum compound.

9. A method of making the abrasive article (10) of any one of claims 1-8, comprising: forming a non-woven web (12) of the fibers or filaments; perforating the web (12); applying the abrasive particles (22) and a binder to the perforated web; and curing the binder, to provide the abrasive article (10).

10. The method of claim 9, wherein forming the non-woven web (12) of fibers comprises air-laying the fibers.

11. A method for removing material from the surface of a workpiece, the method comprising: contacting an abrasive article (10) of any one of claims 1-8, or formed by the method of any one of claims 9 or 10, against the workpiece; and moving the abrasive article (10) relative to the workpiece while maintaining pressure between the abrasive article (10) and the workpiece surface to remove material therefrom.

12. The method of claim 11, wherein the abrasive article (10) is in the shape of a disc having a center axis and moving the abrasive article (10) relative to the workpiece is accomplished by rotating the abrasive article (10) about the center axis.

13. The method of any one of claims 11 or 12, wherein the material removed from the workpiece is carbon steel.

14. The method of any one of claims 11-13, wherein a greater amount of the workpiece is removed than is removed by a corresponding abrasive article, run at the same speed and differing from the abrasive article (10) only by having less heat-activated water-forming inorganic component or no heat-activated water-forming inorganic component.