Surface conditioning articles and method of making same

Abstract

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

What is claimed is:  
     
         1 . A surface conditioning article comprising an all organic matrix having adhered thereto water-base organic binders including a first binder and a second binder with abrasive particles dispersed and adhered within said second binder, wherein the first binder comprises a mixture of a phenolic resin and a carboxylated butadiene-acrylonitrile copolymer latex, in the range of weight ratio of dry materials of said latex versus said phenolic resin of 90/10 to 60/40.  
     
     
         2 . A surface conditioning article according to  claim 1 , wherein said phenolic resin of the first binder is a resole phenolic resin with a water tolerance of at least 500% by weight.  
     
     
         3 . A surface conditioning article according to  claim 1 , wherein said phenolic resin of the first binder has a molecular weight in the range of 100 to 1000.  
     
     
         4 . A surface conditioning article according to  claim 1 , wherein said carboxylated butadiene-acrylonitrile latex has a molar percent of acrylonitrile from 25%to35%.  
     
     
         5 . A surface conditioning article according to  claim 1 , wherein the latex particles have a size in the range of 10 to 500 nm.  
     
     
         6 . A surface conditioning article according to  claim 1  further comprising a third binder coated over the second binder, said third binder comprising a mixture of phenolic resin and carboxylated butadiene acrylonitrile copolymer latex.  
     
     
         7 . A surface conditioning article according to  claim 6 , wherein the weight ratio of dry materials of said latex versus said phenolic resin in the third binder is in the range of 60/40 to 40/60.  
     
     
         8 . A surface conditioning article according to  claim 7 , wherein the phenolic resin and carboxylated butadiene-acrylonitrile latex are the same in the first and third binders.  
     
     
         9 . A surface conditioning article according to  claim 6 , wherein the latex versus phenolic resin weight ratio is of 70/30 in the first binder and 60/40 in the third binder.  
     
     
         10 . A surface conditioning article according to  claim 1 , wherein said organic matrix comprises an open, lofty, three-dimensional nonwoven web.  
     
     
         11 . A surface conditioning article according to  claim 10 , wherein said nonwoven web comprises organic polyester or polyamid fibers.  
     
     
         12 . A surface conditioning article according to  claim 11 , wherein the fibers have a denier from between 10 to 100 and a length from between 10 to 100 mm.