Abrasive article with patterned abrasive particles

Abstract

The present disclosure provides an abrasive article. The abrasive article includes a spunbond web. The spunbond web includes a first major surface and an opposite second major surface and a fiber component. The article further includes a binder dispensed on the fiber component. The article further includes abrasive particles substantially retained by the binder and dispersed about the first major surface of the nonwoven web and substantially forming a predetermined pattern.

1 . An abrasive article comprising:
 a spunbond web comprising:
 a first major surface and an opposite second major surface; 
 a fiber component, defining at least a portion of the first major surface, second major surface, or both and an interior portion of the spunbond web; 
   a binder dispensed on and at least partially penetrating the fiber component, the binder dispensed on the fiber component according to a substantially predetermined pattern; and   abrasive particles substantially retained by the binder and dispersed about the first major surface of the nonwoven web, wherein   the binder and the abrasive particles substantially form a predetermined pattern.   
     
     
         2 . The abrasive article according  claim 1 , wherein individual fibers of the fiber component comprise a material chosen from a polyester, a nylon, a polypropylene, a polyethylene, a polyurethane, a polylactic acid, 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 according to  claim 2 , wherein the individual fibers of the fiber component comprise a polyethylene terephthalate. 
     
     
         4 . The abrasive article according to  claim 1  wherein the binder has initial viscosity is in a range of from about 10,000 cps to about 50,000 cps and the final viscosity is in a range of from about 50,000 cps to about 1,000,000 cps. 
     
     
         5 . The abrasive article according to  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. 
     
     
         6 . The abrasive article according to  claim 1 , wherein the abrasive particles are 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. 
     
     
         7 . The abrasive article according to  claim 1 , wherein a portion of the abrasive particles form a predetermined pattern on the fibrous web within the binder. 
     
     
         8 . The abrasive article according to  claim 1 , wherein the abrasive particles are distributed over about 15% to about 60% of the total surface area of the first major surface, second major surface, or both. 
     
     
         9 . The abrasive article according to  claim 6 , wherein the predetermined pattern comprises a plurality of circles, substantially parallel lines, substantially curved lines, a plurality of hatchings, or a combination thereof. 
     
     
         10 . The abrasive article according to  claim 1 , further comprising a saturant applied to the spunbond web. 
     
     
         11 . The abrasive article according to  claim 10 , wherein the saturant comprises a phenolic resin, an acrylic, a urea resin, or a mixture thereof. 
     
     
         12 . The abrasive article according to  claim 10 , wherein the saturant includes a urea formaldehyde resin. 
     
     
         13 . The abrasive article according to  claim 10 , wherein the saturant includes a urea formaldehyde resin and a compatible latex. 
     
     
         14 . The abrasive article according to  claim 13 , wherein the compatible latex comprises an acrylic emulsion. 
     
     
         15 . The abrasive article according to  claim 1 , further comprising a size layer applied at least partially to the abrasive particles. 
     
     
         16 . The abrasive article according to  claim 15 , wherein the size layer comprises a size binder comprising phenolic resins, melamine resins, aminoplast resins having pendant α-, β-unsaturated carbonyl groups, urethane resins, epoxy resins, ethylenically unsaturated resins, acrylated isocyanurate resins, urea-aldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, bismaleimide resins, fluorene-modified epoxy resins, a urea formaldehyde resin, a phenolic formaldehyde resin, and a melamine formaldehyde resin, and combinations thereof. 
     
     
         17 . A method of forming the abrasive article according to  claim 1 , the method comprising:
 positioning the first major surface or the second major surface of the spunbond web substantially in-line with a perforated screen;   dispersing the binder through individual perforations of the perforated screen to form a plurality of binder pockets arranged in a predetermined pattern on the first major surface of the second major surface; and   contacting the plurality of binder pockets with the abrasive particles,   wherein an initial viscosity of the binder prior to and during dispersing is less than a final viscosity of the binder upon contact with the first major surface or the second surface.   
     
     
         18 . The method according to  claim 17 , further comprising applying the saturant to the spunbond web. 
     
     
         19 . The method according to  claim 17 , wherein the screen comprises a continuous mesh that defines a plurality of perforations for the binder to pass through. 
     
     
         20 . The method according to  claim 17 , wherein the initial viscosity is in a range of from about 10,000 cps to about 50,000 cps and the final viscosity is in a range of from about 50,000 cps to about 1,000,000 cps.