Abrasive articles having improved performance

Abstract

The present disclosure relates to an abrasive article. The abrasive article ( 10 ) includes a non-woven web ( 12 ). The non-woven web ( 12 ) includes a fiber or filament component ( 18 ). The non-woven web ( 12 ) further includes a first major surface ( 14 ) and a second major surface ( 16 ). A thickness of the non-woven web ( 12 ) is defined from the first major surface ( 14 ) to the second major surface ( 16 ). The abrasive article further includes a plurality of shaped abrasive particles ( 22 ) dispersed through at least a portion of the non-woven web ( 12 ). The abrasive article further includes a heat-activated water-forming inorganic component dispersed through the non-woven web ( 12 ).

1 . An abrasive article comprising:
 a non-woven web, comprising:
 a fiber or filament component, 
 a first major surface, and 
 a second major surface, wherein a thickness of the non-woven web is defined from the first major surface to the second major surface; 
   a plurality of individual shaped abrasive particles dispersed through at least a portion of the non-woven web; and   a heat-activated water-forming inorganic component dispersed through the non-woven web.   
     
     
         2 . The abrasive article of  claim 1 , wherein the fibers comprise a material chosen from a polyester, a nylon, a polypropylene, an acrylic, a rayon, a cellulose acetate, a polyvinylidene chloride-vinyl chloride copolymer, a vinyl chloride-acrylonitrile copolymer, and combinations thereof. 
     
     
         3 . The abrasive article of  claim 1 , wherein the individual shaped abrasive particles are distributed throughout the thickness of the non-woven web in a plurality of regions. 
     
     
         4 . The abrasive article of  claim 1 , wherein the individual shaped abrasive particles comprise a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol-gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof. 
     
     
         5 . The abrasive article of  claim 1 , wherein the heat-activated water-forming inorganic component is in a range of from about 1 wt % to about 20 wt % of the abrasive article. 
     
     
         6 . The abrasive article of  claim 1 , wherein the heat-activated water-forming inorganic component is an endothermically heat-activated water-forming inorganic component having an activation temperature of about 300° C. or less. 
     
     
         7 . The abrasive article of  claim 1 , wherein the heat-activated water-forming inorganic component comprises a metal hydroxide. 
     
     
         8 . The abrasive article of  claim 7 , wherein the metal hydroxide is a hydrated aluminum compound. 
     
     
         9 . An abrasive article comprising:
 a non-woven web, comprising:
 a fiber or filament component; 
 a first major surface; 
 a second major surface, wherein a thickness of the non-woven web is defined therebetween; 
   a plurality of individual shaped abrasive particles dispersed through the non-woven web; and   a hydrated aluminum compound dispersed through the non-woven web.   
     
     
         10 . A method of making the abrasive article of  claim 9 , comprising:
 forming a non-woven web of the fibers or filaments;   perforating the web;   applying the abrasive particles and a binder to the perforated web; and   curing the binder, to provide the abrasive article.   
     
     
         11 . The method of  claim 10 , wherein forming the non-woven web of fibers comprises air-laying the fibers. 
     
     
         12 . A method for removing material from the surface of a workpiece, the method comprising:
 contacting an abrasive article of  claim 9 , or formed by the method of any one of  claim 10  or  11 , against the workpiece; and   moving the abrasive article relative to the workpiece while maintaining pressure between the abrasive article and the workpiece surface to remove material therefrom.   
     
     
         13 . The method of  claim 12 , wherein the abrasive article is in the shape of a disc having a center axis and moving the abrasive article relative to the workpiece is accomplished by rotating the abrasive article about the center axis. 
     
     
         14 . The method of  claim 12 , wherein the material removed from the workpiece is carbon steel. 
     
     
         15 . The method of  claim 12 , wherein a greater amount of the workpiece is removed than is removed by a corresponding abrasive article run at the same speed and differing only by having less heat-activated water-forming inorganic component or no heat-activated water-forming inorganic component.