Abrasive article and method of making and using the same

Abstract

An abrasive article comprises a porous abrasive member, a nonwoven filter medium, a second nonwoven filter medium, and optionally a porous attachment layer. A plurality of openings in the porous abrasive member cooperates with the first nonwoven filter medium to allow the flow of particles from an outer abrasive surface of the porous abrasive member to the second nonwoven filter medium. Methods of making and using the abrasive articles are included.

1 . An abrasive article comprising:
 a porous abrasive member comprising: an abrasive layer proximate and affixed to a first surface of a substrate, the abrasive layer comprising a plurality of abrasive particles affixed to the first surface of the substrate by at least one binder, wherein the abrasive layer has an outer abrasive surface, wherein the substrate has a thickness and a second surface opposite the first surface of the substrate, wherein a plurality of openings extend from the outer abrasive surface to the second surface of the substrate, and wherein the porous abrasive member has perforations that extend through the thickness of the substrate and have a substantially uniform cross-section throughout their length;   a unitary first nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first surface of the first nonwoven filter medium is proximate and affixed to the second surface of the substrate, and wherein the first nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof, and   a unitary second nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first surface of the second nonwoven filter medium is proximate and affixed to the second surface of the first nonwoven filter medium, and wherein the second nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof;   wherein the plurality of openings cooperate with the first nonwoven filter medium to allow the flow of particles from the outer abrasive surface to the second nonwoven filter medium, and wherein, in an unused state, the at least a portion of the abrasive article exhibits a pressure drop according to the Pressure Drop Measurement Test in a range of from 0.2 to 20 millimeters of water.   
   
   
       2 . An abrasive article according to  claim 1 , wherein the porous abrasive member comprises an apertured coated abrasive. 
   
   
       3 . An abrasive article according to  claim 1 , wherein the porous abrasive member comprises a screen abrasive. 
   
   
       4 . An abrasive article according to  claim 1 , further comprising a porous attachment layer proximate and affixed to the second surface of the second nonwoven filter medium. 
   
   
       5 . An abrasive article according to  claim 4 , wherein the porous attachment layer comprises a loop portion or a hook portion of a two-part mechanical engagement system. 
   
   
       6 . An abrasive article according to  claim 4 , wherein the first nonwoven filter medium, the second nonwoven filter medium, and the porous attachment layer are affixed to one another by needletacking or a stitch bond. 
   
   
       7 . An abrasive article according to  claim 1 , wherein the first nonwoven filter medium and the second nonwoven filter medium are affixed to one another by needletacking or a stitch bond. 
   
   
       8 . An abrasive article according to  claim 1 , wherein the first nonwoven filter medium is affixed to the second nonwoven filter medium by an adhesive. 
   
   
       9 . An abrasive article according to  claim 1 , wherein at least one of the first or second nonwoven filter medium has a peripheral edge that is sealed along a major portion thereof. 
   
   
       10 . (canceled) 
   
   
       11 . An abrasive article according to  claim 1 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises a blown microfiber web. 
   
   
       12 . An abrasive article according to  claim 1 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises an electret charge. 
   
   
       13 . An abrasive article according to  claim 1 , wherein the substrate is selected from the group consisting of metal foil, paper, fabric, and plastic film. 
   
   
       14 . An abrasive article according to  claim 1 , wherein the abrasive article comprises an abrasive disc. 
   
   
       15 . A method of abrading a surface of a workpiece, the method comprising contacting the surface with an abrasive article according to  claim 1 , and relatively moving the abrasive article and the surface to mechanically modify the surface. 
   
   
       16 . A method of making an abrasive article, the method comprising:
 providing a porous abrasive member comprising: an abrasive layer proximate and affixed to a first surface of a substrate, the abrasive layer comprising a plurality of abrasive particles affixed to the first surface of the substrate by at least one binder, wherein the abrasive layer has an outer abrasive surface, wherein the substrate has a second surface opposite the first surface of the substrate, wherein a plurality of openings extend from the outer abrasive surface to the second surface of the substrate, and wherein the porous abrasive member has perforations that extend through the thickness of the substrate and have a substantially uniform cross-section throughout their length;   providing a unitary first nonwoven filter medium, the first nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof, and wherein the first surface of the first nonwoven filter medium is proximate the second surface of the substrate;   providing a second nonwoven filter medium, the second nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the second nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof, and wherein the first surface of the second nonwoven filter medium is proximate the second surface of the first nonwoven filter medium;   affixing the first nonwoven filter medium to the second surface of the substrate; and   affixing the second nonwoven filter medium to the first nonwoven filter medium;   wherein the plurality of openings cooperate with the first nonwoven filter medium to allow the flow of particles from the outer abrasive surface to the second nonwoven filter medium, and wherein, in an unused state, at least a portion of the abrasive article exhibits a pressure drop according to the Pressure Drop Measurement Test in a range of from 0.2 to 20 millimeters of water.   
   
   
       17 . A method of making an abrasive article according to  claim 16 , wherein the porous abrasive member comprises an apertured coated abrasive. 
   
   
       18 . A method of making an abrasive article according to  claim 16 , wherein the porous abrasive member comprises a screen abrasive. 
   
   
       19 . A method of making an abrasive article according to  claim 16 , the method further comprising sealing a major portion of a peripheral edge of at least one of the first or second nonwoven filter medium. 
   
   
       20 . A method of making an abrasive article according to  claim 16 , further comprising affixing a porous attachment layer to the second nonwoven filter medium. 
   
   
       21 . A method of making an abrasive article according to  claim 20 , wherein the porous attachment layer comprises a loop portion or a hook portion of a two-part mechanical engagement system. 
   
   
       22 . A method of making an abrasive article according to  claim 20 , wherein the first nonwoven filter medium, the second nonwoven filter medium, and the porous attachment layer are affixed to one another by needletacking or a stitch bond. 
   
   
       23 . A method of making an abrasive article according to  claim 16 , wherein the first nonwoven filter medium and the second nonwoven filter medium are affixed to one another by needletacking or a stitch bond. 
   
   
       24 . A method of making an abrasive article according to  claim 16 , wherein the porous abrasive member is affixed to the first nonwoven filter medium by an adhesive. 
   
   
       25 . A method of making an abrasive article according to  claim 16 , wherein the first nonwoven filter medium is affixed to the second nonwoven filter medium by an adhesive. 
   
   
       26 . (canceled) 
   
   
       27 . A method of making an abrasive article according to  claim 16 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises a blown microfiber web. 
   
   
       28 . A method of making an abrasive article according to  claim 16 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises an electret charge. 
   
   
       29 . A method of making an abrasive article according to  claim 16 , wherein the substrate is selected from the group consisting of metal foil, paper, fabric, and plastic film. 
   
   
       30 . A method of making an abrasive article according to  claim 16 , wherein the abrasive article comprises an abrasive disc. 
   
   
       31 . An abrasive article comprising:
 a porous abrasive member comprising: an abrasive layer proximate and affixed to a first surface of a substrate, the abrasive layer comprising a plurality of abrasive particles affixed to the first surface of the substrate by at least one binder, wherein the abrasive layer has an outer abrasive surface, wherein the substrate has a thickness and a second surface opposite the first surface of the substrate, wherein a plurality of openings extend from the outer abrasive surface to the second surface of the substrate, and wherein the porous abrasive member has perforations that extend through the thickness of the substrate and have a substantially uniform cross-section throughout their length;   a unitary first nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first surface of the first nonwoven filter medium is proximate and affixed to the second surface of the substrate, wherein the first nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof, and wherein the first nonwoven filter medium has a thickness of from 1 to 25 millimeters and a density of from 0.04 to 0.5 grams per cubic centimeter; and   a unitary second nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first surface of the second nonwoven filter medium is proximate and affixed to the second surface of the first nonwoven filter medium, wherein the second nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof, and wherein the second nonwoven filter medium has a thickness of from 0.5 to 15 millimeters and a bulk density of from 0.04 to 0.5 grams per cubic centimeter; and   wherein the plurality of openings cooperate with the first nonwoven filter medium to allow the flow of particles from the outer abrasive surface to the second nonwoven filter medium.   
   
   
       32 . An abrasive article according to  claim 31 , wherein the porous abrasive member comprises an apertured coated abrasive. 
   
   
       33 . An abrasive article according to  claim 31 , wherein the porous abrasive member comprises a screen abrasive. 
   
   
       34 . An abrasive article according to  claim 31 , further comprising a porous attachment layer proximate and affixed to the second surface of the second nonwoven filter medium. 
   
   
       35 . An abrasive article according to  claim 34 , wherein the porous attachment layer comprises a loop portion or a hook portion of a two-part mechanical engagement system. 
   
   
       36 . An abrasive article according to  claim 34 , wherein the first nonwoven filter medium, the second nonwoven filter medium, and the porous attachment layer are affixed to one another by needletacking or a stitch bond. 
   
   
       37 . An abrasive article according to  claim 31 , wherein the first nonwoven filter medium and the second nonwoven filter medium are affixed to one another by needletacking or a stitch bond. 
   
   
       38 . An abrasive article according to  claim 31 , wherein the porous abrasive member is affixed to the first nonwoven filter medium by an adhesive. 
   
   
       39 . An abrasive article according to  claim 31 , wherein the first nonwoven filter medium is affixed to the second nonwoven filter medium by an adhesive. 
   
   
       40 . An abrasive article according to  claim 31 , wherein at least one of the first or second nonwoven filter medium has a peripheral edge that is sealed along a major portion thereof. 
   
   
       42 . (canceled) 
   
   
       43 . An abrasive article according to  claim 31 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises a blown microfiber web. 
   
   
       44 . An abrasive article according to  claim 31 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises an electret charge. 
   
   
       45 . An abrasive article according to  claim 31 , wherein the substrate is selected from the group consisting of metal foil, paper, fabric, and plastic film. 
   
   
       46 . An abrasive article according to  claim 31 , wherein the abrasive article comprises an abrasive disc. 
   
   
       47 . A method of abrading a surface of a workpiece, the method comprising contacting the surface with an abrasive article according to  claim 31 , and relatively moving the abrasive article and the surface to mechanically modify the surface. 
   
   
       48 . A method of making an abrasive article, the method comprising:
 providing a porous abrasive member comprising: an abrasive layer proximate and affixed to a first surface of a substrate, the abrasive layer comprising a plurality of abrasive particles affixed to the first surface of the substrate by at least one binder, wherein the abrasive layer has an outer abrasive surface, wherein the substrate has a second surface opposite the first surface of the substrate, wherein a plurality of openings extend from the outer abrasive surface to the second surface of the substrate, and wherein the porous abrasive member has perforations that extend through the thickness of the substrate and have a substantially uniform cross-section throughout their length;   providing a unitary first nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first surface of the first nonwoven filter medium is proximate the second surface of the substrate, wherein the first nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof, and wherein the first nonwoven filter medium has a thickness of from 1 to 25 millimeters and a bulk density of from 0.04 to 0.5 grams per cubic centimeter:   providing a unitary second nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first surface of the second nonwoven filter medium is proximate the second surface of the first nonwoven filter medium, wherein the second nonwoven filter medium comprises a plurality of synthetic fibers selected from the group consisting of polypropylene fibers, polyester fibers, nylon fibers, and mixtures thereof, wherein the second nonwoven filter medium has a thickness of from 0.5 to 15 millimeters and a bulk density of from 0.04 to 0.5 grams per cubic centimeter;   affixing the first nonwoven filter medium to the second surface of the substrate; and   affixing the second nonwoven filter medium to the first nonwoven filter medium,   wherein the plurality of openings cooperate with the first nonwoven filter medium to allow the flow of particles from the outer abrasive surface to the second nonwoven filter medium.   
   
   
       49 . A method of making an abrasive article according to  claim 48 , wherein the porous abrasive member comprises an apertured coated abrasive. 
   
   
       50 . A method of making an abrasive article according to  claim 48 , wherein the porous abrasive member comprises a screen abrasive. 
   
   
       51 . A method of making an abrasive article according to  claim 48 , the method further comprising sealing a major portion of a peripheral edge of at least one of the first or second nonwoven filter medium. 
   
   
       52 . A method of making abrasive article according to  claim 48 , further comprising affixing a porous attachment layer to the second nonwoven filter medium. 
   
   
       53 . A method of making abrasive article according to  claim 52 , wherein the porous attachment layer comprises a loop portion or a hook portion of a two-part mechanical engagement system. 
   
   
       54 . A method of making an abrasive article according to  claim 52 , wherein the first nonwoven filter medium, the second nonwoven filter medium, and the porous attachment layer are affixed to one another by needletacking or a stitch bond. 
   
   
       55 . A method of making an abrasive article according to  claim 48 , wherein the first nonwoven filter medium and the second nonwoven filter medium are affixed to one another by needletacking or a stitch bond. 
   
   
       56 . A method of making an abrasive article according to  claim 48 , wherein the porous abrasive member is affixed to the first nonwoven filter medium by an adhesive. 
   
   
       57 . A method of making an abrasive article according to  claim 48 , wherein the first nonwoven filter medium is affixed to the second nonwoven filter medium by an adhesive. 
   
   
       58 . (canceled) 
   
   
       59 . A method of making an abrasive article according to  claim 48 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises a blown microfiber web. 
   
   
       60 . A method of making an abrasive article according to  claim 48 , wherein at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises an electret charge. 
   
   
       61 . A method of making an abrasive article according to  claim 48 , wherein the substrate is selected from the group consisting of metal foil, paper, fabric, and plastic film. 
   
   
       62 . A method of making an abrasive article according to  claim 48 , wherein the abrasive article comprises an abrasive disc.