Nonwoven abrasive articles and methods for making and using the same

Abstract

Nonwoven abrasive articles comprise a porous reinforcing material, a fiber web affixed to the porous reinforcing material, abrasive particles, and a non-elastomeric binder. Methods of making and using nonwoven abrasive articles are also disclosed.

What is claimed is:  
     
         1 . A nonwoven abrasive article comprising: 
 a porous reinforcing material having first and second opposed major surfaces;    a fiber web, wherein the fiber web is affixed to the first major surface of the porous reinforcing material; and    an abrasive composition comprising abrasive particles and a non-elastomeric binder, wherein the abrasive composition contacts at least a portion of the fiber web and the first major surface of the porous reinforcing material, wherein the abrasive composition extends through at least a portion of the porous reinforcing material and contacts at least a portion of the second major surface of the porous reinforcing material, and wherein, on a weight basis, there is a first average ratio of abrasive particles to the non-elastomeric binder at the first major surface, and a second average ratio of abrasive particles to the non-elastomeric binder at the second major surface, and wherein the first average ratio is greater than the second average ratio.    
     
     
         2 . A nonwoven abrasive article according to  claim 1 , wherein the fiber web is needletacked to the first major surface of the porous reinforcing material.  
     
     
         3 . A nonwoven abrasive article according to  claim 1 , wherein the article is a disc.  
     
     
         4 . A nonwoven abrasive article according to  claim 1 , wherein the article is an endless belt.  
     
     
         5 . A nonwoven abrasive article according to  claim 1 , wherein the binder comprises at least partially cured phenolic resin.  
     
     
         6 . A nonwoven abrasive article according to  claim 1 , wherein the abrasive composition comprises a slurry coat.  
     
     
         7 . A nonwoven abrasive article according to  claim 6 , further comprising a size coat contacting at least a portion of the abrasive composition.  
     
     
         8 . A nonwoven abrasive article according to  claim 6 , wherein the size coat comprises an elastomer.  
     
     
         9 . A nonwoven abrasive article according to  claim 6 , wherein the size coat comprises at least one of a lubricant or a grinding aid.  
     
     
         10 . A nonwoven abrasive article according to  claim 7 , wherein the article comprises a disc or an endless belt.  
     
     
         11 . A nonwoven abrasive article according to  claim 1 , wherein the abrasive composition comprises a make coat and a size coat.  
     
     
         12 . A nonwoven abrasive article according to  claim 11 , wherein the size coat comprises an elastomer.  
     
     
         13 . A nonwoven abrasive article according to  claim 11 , wherein the size coat comprises at least one of a lubricant or a grinding aid.  
     
     
         14 . A nonwoven abrasive article according to  claim 11 , wherein the article is a disc or an endless belt.  
     
     
         15 . A nonwoven abrasive article according to  claim 11 , wherein the first binder comprises at least partially cured phenolic resin.  
     
     
         16 . A method for making a nonwoven abrasive article comprising: 
 providing a fiber web;    providing a porous reinforcing material having first and second opposed major surfaces;    affixing the fiber web to the first major surface of the reinforcing material;    applying a first binder precursor and abrasive particles onto the fiber web, wherein at least a portion of the first binder precursor penetrates through the porous reinforcing material and contacts at least a portion of the first and second major surfaces; and    at least partially curing the first binder precursor to form a non-elastomeric first binder, wherein on a weight basis, there is a first average ratio of abrasive particles to the non-elastomeric binder at the first major surface, and a second average ratio of abrasive particles to the non-elastomeric binder at the second major surface, and wherein the first average ratio is greater than the second average ratio.    
     
     
         17 . A method according to  claim 16 , wherein affixing comprises needletacking.  
     
     
         18 . A method according to  claim 16 , wherein applying comprises spraying.  
     
     
         19 . A method according to  claim 16 , further comprising forming the nonwoven abrasive article into at least one of a disc or an endless belt.  
     
     
         20 . A method according to  claim 16 , wherein the first binder precursor comprises phenolic resin.  
     
     
         21 . A method according to  claim 16 , wherein the first binder precursor and abrasive particles comprise a slurry coat precursor.  
     
     
         22 . A method according to  claim 16 , wherein the first binder precursor comprises a make coat precursor.  
     
     
         23 . A method according to  claim 16 , further comprising: 
 applying a second binder precursor to at least a portion of the non-elastomeric first binder, wherein the second binder precursor; and    at least partially curing the second binder precursor.    
     
     
         24 . A method according to  claim 23 , further comprising forming the nonwoven abrasive article into at least one of a disc or an endless belt.  
     
     
         25 . A method according to  claim 23 , wherein the second binder precursor is at least partially curable to form an elastomer.  
     
     
         26 . A method of abrading a surface, the method comprising: 
 providing a nonwoven abrasive article, wherein the nonwoven abrasive article comprises: 
 a porous reinforcing material having first and second opposed major surfaces;  
 a fiber web affixed to the first major surface of the porous reinforcing material;  
 an abrasive composition comprising abrasive particles and binder, wherein the abrasive composition contacts at least a portion of the fiber web and the first major surface of the reinforcing material, wherein the abrasive composition extends through at least a portion of the reinforcing material and contacts at least a portion of the second major surface of the reinforcing material, wherein on a weight basis, there is a first average ratio of abrasive particles to the non-elastomeric binder at the first major surface, and a second average ratio of abrasive particles to the non-elastomeric binder at the second major surface, and wherein the first average ratio is greater than the second average ratio;  
   contacting at least one of the abrasive particles with the surface of the workpiece; and    moving at least one of the abrasive particles or the contacted surface relative to the other to abrade at least a portion of the contacted surface.    
     
     
         27 . A method of abrading a workpiece according to  claim 26 , wherein the nonwoven abrasive article further comprises a size coat contacting at least a portion of the slurry coat.  
     
     
         28 . A method of abrading a workpiece according to  claim 26 , wherein the first binder comprises at least partially cured phenolic resin.