Nonwoven composite abrasive comprising diamond abrasive particles

Patent metadata

Field	Value
Publication number	US-9266221-B2
Application number	US-201113267465-A
Country	US
Kind code	B2
Filing date	Oct 6, 2011
Priority date	Oct 6, 2010
Publication date	Feb 23, 2016
Grant date	Feb 23, 2016

Abstract

An abrasive article includes a support, a first polymeric binder, a second polymeric binder, and abrasive particles. The support includes a plurality of nonwoven layers. A method of forming an abrasive article includes providing a support including, applying a first coating of the first polymeric binder to the support, applying superabrasive particles to the coated support, applying a layer of a second polymeric binder overlying the superabrasive particles. The method further includes compressing the support and applying heat to cure the first polymeric binder. A method of preparing a work piece includes applying a thermal spray coating to the work piece, and polishing the thermal spray coating with the abrasive article.

First claim

What is claimed is:

1. An abrasive article comprising:
a support comprising a plurality of nonwoven layers, each nonwoven layer comprising a plurality of fibers;
a first polymeric binder disposed on the fibers, wherein the first polymeric binder includes a polyurethane resin and a phenoxy resin;
abrasive particles having a Mohs hardness of at least about 8.0 disposed on the first polymeric binder;
a second polymeric binder disposed on the abrasive particles and the first polymeric binder, wherein the second polymeric binder comprises a phenolic resin; and
a third polymeric binder disposed on the second polymeric binder, wherein the third polymeric binder includes a polyurethane resin and a phenoxy resin.

2. The abrasive article of claim 1 , wherein the space between the abrasive particles and the support is substantially free of the second polymeric binder.

3. The abrasive article of claim 1 , wherein the abrasive article is in the form of a wheel.

4. The abrasive article of claim 1 , wherein the plurality of nonwoven layers includes about 2 to about 50 nonwoven layers.

5. The abrasive article of claim 1 , wherein the fibers are bonded by a further polymeric binder disposed on the fibers between the fibers and the first polymeric binder, wherein the further polymeric binder comprises an acrylic resin.

6. The abrasive article of claim 1 , wherein a nonwoven layer of the plurality of nonwoven layers has a thickness of at least 0.5 mm.

7. The abrasive article of claim 1 , wherein abrasive article has an open structure.

8. The abrasive article of claim 7 , wherein the abrasive article has at least 25% open volume.

9. The abrasive article of claim 1 , wherein the abrasive article has a hardness in a range of 20 kgf/25% compression to 90 kgf/25% compression.

10. An abrasive article comprising:
a support comprising about 2 to about 50 nonwoven layers, wherein each nonwoven layer comprises a plurality of fibers;
a first polymeric binder disposed on the fibers, wherein the first polymeric binder includes a polyurethane resin and a phenoxy resin;
a plurality of superabrasive particles disposed on the first polymeric binder;
a second polymeric binder disposed on the first polymeric binder and the plurality of superabrasive particles, wherein the second polymeric binder comprises a phenolic resin; and
a third polymeric binder disposed on the second polymeric binder, wherein polymeric binder includes a polyurethane resin and a phenoxy resin
wherein the plurality of fibers is bonded together by a further polymeric binder disposed on the fibers between the fibers and the first polymeric binder, wherein the further polymeric binder comprises an acrylic latex or a polyurethane latex resin,
wherein the abrasive article has a hardness in a range of 20 kgf/25% compression to 90 kgf/25% compression, and
wherein the abrasive article is in the form of a wheel and has an open structure.

11. A method of forming an abrasive article, comprising:
providing a support comprising a plurality of nonwoven layers, each nonwoven layer comprising a plurality of fibers;
applying a first coating of a first polymeric binder to the fibers wherein the first polymeric binder includes a polyurethane resin and a phenoxy resin;
applying abrasive particles to the coating of first polymeric binder;
applying a layer of a second polymeric binder over the abrasive particles and the coating of first polymeric binder, wherein the second polymer layer is a phenolic resin;
applying a layer of a third polymeric binder over the second polymeric binder, wherein the third polymeric binder includes a polyurethane resin and a phenoxy resin;
compressing the support; and
applying heat to cure the polymeric binders.

12. The method of claim 11 , wherein applying the first coating of the first polymeric binder includes dipping the support into the first polymeric binder and squeezing the support to remove a portion of the first polymeric binder from the support.

13. The method of claim 11 , further comprising applying a second coating of the first polymeric binder on the layer of the second polymeric binder.

14. The method of claim 11 , further comprising cutting the abrasive article into the form of a wheel.

15. The method of claim 11 , wherein providing the support includes:
forming a plurality of fibers into a plurality of nonwoven layers; binding the plurality of fibers together with a further polymeric binder; and
stacking the plurality of nonwoven layers to form the support.

Assignees

• Hsu Shyiguei
• Gomez Alejandro
• Pinto Fabio De A
• Stockton John E
• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Hsu Shyiguei
• Gomez Alejandro
• Pinto Fabio De A
• Stockton John E

Classifications

• B24D11/02

  Backings, e.g. foils, webs, mesh fabrics · CPC title

• B24B37/24

  characterised by the composition or properties of the pad materials · CPC title

• B24D3/28 Primary

  Resins {or natural or synthetic macromolecular compounds (B24D3/22 takes precedence)} · CPC title

• B24D18/00

  Manufacture of grinding tools {or other grinding devices}, e.g. wheels, not otherwise provided for · CPC title