Nonwoven abrasive articles and methods of making the same

Patent metadata

Field	Value
Publication number	US-10850368-B2
Application number	US-201916523419-A
Country	US
Kind code	B2
Filing date	Jul 26, 2019
Priority date	Mar 29, 2013
Publication date	Dec 1, 2020
Grant date	Dec 1, 2020

Abstract

Nonwoven abrasive articles comprise a nonwoven abrasive member having an overlayer composition comprising a fatty acid metal salt disposed thereon adjacent to a working surface. The nonwoven abrasive member comprises abrasive particles adhered to a fiber web by a binder. The abrasive particles may be exposed and/or the nonwoven abrasive member may have suitable frictional properties. Methods of making the same are also disclosed.

First claim

What is claimed is:

1. A nonwoven abrasive article comprising:
a nonwoven abrasive member having a working surface, wherein the nonwoven abrasive member comprises:
a lofty open fiber web comprising fibers bonded to one another; and
abrasive particles adhered to the fibers by a binder material, and wherein at least a portion of the abrasive particles form a visible outer later, wherein the abrasive particles are closely packed, and wherein on a numerical basis at least 80 percent of the abrasive particles in the visible outer layer have recognizable outlines wherein the working surface of the nonwoven abrasive member has a kinetic coefficient of friction of at least 0.54 according to a FRICTION TEST comprising:
a first test specimen of the nonwoven abrasive member, attached to a metal weight and a second test specimen of polymethyl methacrylate (PMMA) disc, attached to a horizontal test stage, are equilibrated for at least 24 hours at 17 percent relative humidity and 25° C. prior to use;
the first test specimen is place such that a working surface is in contact with the PMMA disc and attached to the load cell of a friction testing machine at 17 percent relative humidity and 25° C.; and
a horizontal force is applied by the friction testing machine at a horizontal stage translational speed of 31 cm/minute and the kinetic coefficient of friction is determined as the average kinetic coefficient of friction over a 5-second interval; and

an overlayer composition disposed on at least a portion of the binder material and abrasive particles adjacent to the working surface thereby forming the nonwoven abrasive article, wherein the overlayer composition comprises a fatty acid metal salt.

2. The nonwoven abrasive article of claim 1 , wherein the overlayer composition has a basis weight of at least 2.5 grams per square meter.

3. The nonwoven abrasive article of claim 2 , wherein the abrasive particles conform to an abrasives industry specified nominal grade.

4. The nonwoven abrasive article of claim 1 , wherein the overlayer composition further comprises a polymeric resin.

5. The nonwoven abrasive article of claim 1 , wherein the abrasive particles have an average particle size of at least 5 microns.

6. The nonwoven abrasive article of claim 1 , wherein the abrasive particles have an average particle size of less than or equal to 125 microns.

7. A method of making an abrasive article, the method comprising sequentially:
providing a nonwoven abrasive member having a working surface, wherein the nonwoven abrasive member comprises:
a lofty open fiber web comprising fibers bonded to one another;
abrasive particles adhered to the fibers by a binder material, and wherein at least a portion of the abrasive particles form a visible outer later, wherein the abrasive particles are closely packed, and wherein on a numerical basis at least 80 percent of the abrasive particles in the visible outer layer have recognizable outlines wherein the working surface of the nonwoven abrasive member has a kinetic coefficient of friction of at least 0.54 according to a FRICTION TEST comprising:
a first test specimen of the nonwoven abrasive member, attached to a metal weight and a second test specimen of polymethyl methacrylate (PMMA) disc, attached to a horizontal test stage, are equilibrated for at least 24 hours at 17 percent relative humidity and 25° C. prior to use;
the first test specimen is place such that a working surface is in contact with the PMMA disc and attached to the load cell of a friction testing machine at 17 percent relative humidity and 25° C.; and
a horizontal force is applied by the friction testing machine at a horizontal stage translational speed of 31 cm/minute and the kinetic coefficient of friction is determined as the average kinetic coefficient of friction over a 5-second interval; and

disposing an overlayer composition on at least a portion of the binder material and the abrasive particles adjacent to the working surface thereby forming the nonwoven abrasive article, wherein the overlayer composition comprises a fatty acid metal salt.

8. The method of claim 7 , wherein the overlayer composition has a basis weight of at least 2.5 grams per square meter.

9. A method of making an abrasive article, the method comprising:
a) providing a nonwoven abrasive member having a working surface, wherein the nonwoven abrasive member comprises:

a lofty open fiber web comprising fibers bonded to one another; and
abrasive particles adhered to at least a portion of the fibers by a binder material, wherein at least a portion of the abrasive particles are at least partially embedded in the binder material and wherein at least a portion of the abrasive particles form a visible outer later, wherein the abrasive particles are closely packed, and wherein on a numerical basis at least 80 percent of the abrasive particles in the visible outer layer have recognizable outlines; and
b) plasma-etching a portion of the binder material adjacent to the working surface to expose portions of the abrasive particles previously embedded in the binder material to provide a plasma-etched nonwoven abrasive member; and
c) disposing an overlayer composition on at least a portion of the working surface of the plasma-etched nonwoven abrasive member, wherein the overlayer composition comprises a fatty acid metal salt.

10. The method of claim 9 , wherein the abrasive particles have an average particle size of less than or equal to 125 microns.

11. The method of claim 9 , wherein the overlayer composition has a basis weight of at least 2.5 grams per square meter.

Assignees

• 3M Innovative Properties Co

Inventors

• Woo Edward J
• Fedorova Nataliya V
• Martinez Jaime A
• Baum Scott A

Classifications

• F02M43/00

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• F02D2041/1434

  Inverse model · CPC title

• B24D11/001

  Manufacture of flexible abrasive materials · CPC title

• B24D18/0027

  by impregnation · CPC title

• F02B29/0418

  the intake air cooler having a bypass or multiple flow paths within the heat exchanger to vary the effective heat transfer surface · CPC title