Fixed abrasive buff

Abstract

Systems and methods including providing a fixed abrasive buff having a central hub and a plurality of fabric layers affixed to the central hub. An abrasive composition is dispersed throughout the fabric layers and includes a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder. The content of the abrasive particles at an outer edge of the plurality of fabric layers is higher than the content of the abrasive particles at an inner edge of the plurality of fabric layers.

What is claimed is: 
     
         1 . A fixed abrasive buff, comprising:
 a central hub;   a plurality of fabric layers affixed to the central hub; and   an abrasive composition comprising a polymeric binder and a plurality of abrasive particles dispersed in the polymeric binder, wherein a content of the abrasive particles at an outer edge of the plurality of fabric layers is higher than the content of the abrasive particles at an inner edge of the plurality of fabric layers.   
     
     
         2 . The fixed abrasive buff of  claim 1 , wherein the content of the abrasive particles at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the content of the abrasive particles at the inner edge of the plurality of fabric layers. 
     
     
         3 . The fixed abrasive buff of  claim 1 , wherein the add-on weight of the abrasive composition at the outer edge of the plurality of fabric layers is higher than the add-on weight of the abrasive composition at the inner edge of the plurality of fabric layers. 
     
     
         4 . The fixed abrasive buff of  claim 3 , wherein the add-on weight of the abrasive composition at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the add-on weight of the abrasive composition at the inner edge of the plurality of fabric layers. 
     
     
         5 . The fixed abrasive buff of  claim 1 , wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is higher than the total weight at the inner edge of the plurality of fabric layers. 
     
     
         6 . The fixed abrasive buff of  claim 5 , wherein the total weight of the fixed abrasive buff at the outer edge of the plurality of fabric layers is at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% higher than the total weight at the inner edge of the plurality of fabric layers. 
     
     
         7 . The fixed abrasive buff of  claim 1 , wherein the inner edge is adjacent the central hub, and wherein the outer edge is radially furthest from the central hub. 
     
     
         8 . The fixed abrasive buff of  claim 1 , wherein the plurality of fabric layers comprises a woven fabric, a nonwoven fabric, or a combination thereof. 
     
     
         9 . The fixed abrasive buff of  claim 8 , wherein the plurality of fabric layers comprises at least 2 layers, at least 4 layers, at least 6 layers, at least 8 layers, at least 10 layers, at least 12 layers, at least 15 layers, at least 20 layers, or at least 25 layers to not greater than 100 layers, not greater than 50 layers, not greater than 25 layers, not greater than 20 layers, not greater than 15 layers, or not greater than 12 layers. 
     
     
         10 . The fixed abrasive buff of  claim 9 , wherein the abrasive composition is dispersed on or in each of the plurality of fabric layers. 
     
     
         11 . The fixed abrasive buff of  claim 1 , wherein the abrasive composition comprises:
 10 wt. % to 80 wt. % of the polymeric binder; and   20 wt. % to 90 wt. % of abrasive particles.   
     
     
         12 . The fixed abrasive buff of  claim 11 , wherein the polymeric binder comprises a self-crosslinking carboxylated styrene-butadiene composition. 
     
     
         13 . The fixed abrasive buff of  claim 11 , wherein the abrasive particles comprise silica, alumina (fused or sintered), zirconia, zirconia/alumina oxides, zirconium silicate, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery, or a combination thereof. 
     
     
         14 . The fixed abrasive buff of  claim 13 , wherein the abrasive particles comprise an average particle size of at least 5 micrometers, at least 10 micrometers, at least 15 micrometers, at least 20 micrometers, or at least 25 micrometers. 
     
     
         15 . The fixed abrasive buff of  claim 14 , wherein the abrasive particles comprise an average particle size of not greater than 500 micrometers, not greater than 250 micrometers, not greater than 100 micrometers, or not greater than 50 micrometers. 
     
     
         16 . A method of forming a fixed abrasive buff, comprising:
 providing an uncoated buff comprising a central hub and a plurality of fabric layers affixed to the central hub;   applying pressure to the plurality of fabric layers to cause the plurality of fabric layers to splay; and   rotating the buff within an abrasive composition to coat the buff with the abrasive composition.   
     
     
         17 . The method of  claim 16 , wherein a content of the abrasive particles at an outer edge of the plurality of fabric layers is higher than the content of the abrasive particles at an inner edge of the plurality of fabric layers. 
     
     
         18 . The method of  claim 16 , wherein the add-on weight of the abrasive composition at the outer edge of the plurality of fabric layers is higher than the add-on weight of the abrasive composition at the inner edge of the plurality of fabric layers. 
     
     
         19 . The method of  claim 16 , applying pressure to the plurality of fabric layers is accomplished by applying pressurized air towards the plurality of fabric layers, pressing the plurality of fabric layers against a sidewall of a container holding the abrasive composition, or a combination thereof. 
     
     
         20 . The method of  claim 16 , further comprising: removing the fixed abrasive buff from the abrasive composition; rotating the fixed abrasive buff to spin off excess abrasive composition; and curing the abrasive composition on the fixed abrasive buff.