Large denier nonwoven fiber webs

Abstract

Various embodiments disclosed relate to an abrasive article. The abrasive article includes a nonwoven web. The nonwoven web includes a first irregular major surface and an opposite second irregular major surface. The nonwoven web further includes a fiber component comprising staple fibers having a linear density ranging from about 50 denier to about 2000 denier and a crimp index value ranging from about 15% to about 60%. The nonwoven web further includes a binder dispensed on the fiber component and abrasive particles dispersed throughout the nonwoven web.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a nonwoven web comprising:
 a first irregular major surface and an opposite second irregular major surface, wherein at least one of the first irregular major surface or second irregular major surfaces comprise a non-planar contour, wherein at least one of the first irregular major surface and the second irregular major surface are substantially free of planar agglomerations of fibers; 
 a fiber component comprising a blend of first staple fibers having a linear density ranging from about 20 denier to about 120 denier and second staple fibers having a linear density ranging from about 400 denier to about 1000 denier; 
 a binder dispensed on the fiber component; and 
 abrasive particles dispersed throughout the nonwoven web. 
   
     
     
         2 . The abrasive article of  claim 1 , wherein the fiber component ranges from about 5 weight percent to about 30 weight percent of the abrasive article. 
     
     
         3 . The abrasive article of  claim 1 , wherein the first staple fibers and the second staple fibers make up from about 70 weight percent to about 100 weight percent of the fiber component. 
     
     
         4 . The abrasive article of  claim 1 , wherein the first staple fibers and the second staple fibers have a length ranging from about 35 millimeters to about 155 millimeters. 
     
     
         5 . The abrasive article of  claim 1 , wherein a crimp index value of the first staple fibers and the second staple fibers ranges from about 15% to about 60%. 
     
     
         6 . The abrasive article of  claim 1 , wherein the first staple fibers and the second staple fibers differ in at least one of a crimp index or a length. 
     
     
         7 . The abrasive article of  claim 1 , wherein the first staple fibers make up from about 5 weight percent to about 40 weight percent of the fiber component. 
     
     
         8 . The abrasive article of  claim 1 , wherein the second staple fibers make up from about 60 weight percent to about 95 weight percent of the fiber component. 
     
     
         9 . The abrasive article of  claim 1 , wherein the first staple fibers and the second staple fibers are randomly oriented and adhesively bonded together at points of mutual contact. 
     
     
         10 . The abrasive article of  claim 1 , wherein the first staple fibers and the second staple fibers are 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. 
     
     
         11 . The abrasive article of  claim 1 , wherein the abrasive particles range from about 5 weight percent to about 70 weight percent of the abrasive article. 
     
     
         12 . The abrasive article of  claim 1 , wherein the abrasive particles are formed ceramic abrasive particles. 
     
     
         13 . The abrasive article of  claim 1 , wherein the abrasive particles include crushed abrasive particles. 
     
     
         14 . The abrasive article of  claim 1 , wherein the 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. 
     
     
         15 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a material chosen from silicon carbide, aluminum oxide, and combinations thereof. 
     
     
         16 . The abrasive article of  claim 1 , wherein the abrasive article is a wheel. 
     
     
         17 . The abrasive article of  claim 1 , wherein the binder is chosen from a polyurethane resin, a polyurethane-urea resin, an epoxy resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, and combinations thereof. 
     
     
         18 . The abrasive article of  claim 1 , wherein the binder ranges from about 10 weight percent to about 70 weight percent of the abrasive article. 
     
     
         19 . A method of making the abrasive article of  claim 1 , the method comprising:
 forming a web of the first staple fibers and the second staple fibers;   perforating the web;   applying the abrasive particles and the binder to the perforated web; and   curing the binder, to provide the abrasive article.   
     
     
         20 . A method for removing material from the surface of a workpiece, the method comprising:
 contacting an abrasive article according to  claim 1  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.