Nonwoven abrasive article and methods of making the same

Abstract

A nonwoven abrasive article includes a prebond composition disposed on a lofty open nonwoven fiber web, an abrasive layer disposed on and secured to at least a portion of the prebond composition. The abrasive layer comprises a binder composition retaining abrasive particles. At least one of the prebond composition and the binder composition comprises a reaction product of a polymer having a plurality of oxazolinyl groups. Methods of making the nonwoven abrasive article are also disclosed.

1 . A nonwoven abrasive article comprising:
 a lofty open nonwoven fiber web;   a prebond composition disposed on at least a portion of the lofty open nonwoven fiber web,   
       an abrasive layer disposed on and secured to at least a portion of the prebond composition, wherein the abrasive layer comprises a binder composition retaining abrasive particles, wherein at least one of the prebond composition and the binder composition comprises a reaction product of a polymer having a plurality of oxazolinyl groups. 
     
     
         2 . The nonwoven abrasive article of  claim 1 , wherein the polymer having a plurality of oxazolinyl groups comprises a (meth)acrylic polymer. 
     
     
         3 . (canceled) 
     
     
         4 . The nonwoven abrasive article of  claim 1 , wherein the polymer having a plurality of oxazolinyl groups is at an amount of at least 1 part per hundred parts of resin (PHR). 
     
     
         5 . (canceled) 
     
     
         6 . The nonwoven abrasive article of  claim 1 , wherein the prebond composition comprises a reaction product of a polymer having a plurality of oxazolinyl groups and a polyurethane having a plurality of carboxyl groups, wherein, on a solids basis, the polymer having a plurality of oxazolinyl groups and the polyurethane are present in a weight ratio of from 1:99 to 8:92. 
     
     
         7 . (canceled) 
     
     
         8 . The nonwoven abrasive article of  claim 1 , wherein the binder composition comprises phenolic. 
     
     
         9 . The nonwoven abrasive article of  claim 1 , wherein the nonwoven abrasive article comprises a nonwoven abrasive disc. 
     
     
         10 . The nonwoven abrasive article of  claim 1 , wherein the lofty open nonwoven fiber web comprises polyamide. 
     
     
         11 . A method of making a nonwoven abrasive article, the method comprising:
 disposing a curable prebond precursor composition on at least a portion of a lofty open nonwoven fiber web,   at least partially curing the curable prebond precursor composition to provide a prebond composition;   disposing and securing an abrasive layer on at least a portion of the prebond composition, wherein the abrasive layer comprises a binder composition retaining abrasive particles;   wherein at least one of the curable prebond precursor composition and the abrasive layer comprises a polymer having a plurality of oxazolinyl groups.   
     
     
         12 . The method of  claim 11 , wherein disposing and securing the abrasive layer on at least a portion of the prebond composition comprises:
 disposing a curable make layer precursor composition onto at least a portion of the prebond composition, wherein the curable make layer precursor composition comprises phenolic resin;   wherein at least one of the curable prebond precursor composition and the curable make layer precursor composition comprises a polymer having a plurality of oxazolinyl groups;   at least partially embedding abrasive particles into the curable make layer precursor composition; and   at least partially curing the curable make layer precursor composition to provide an at least partially cured make layer composition.   
     
     
         13 . The method of  claim 11 , wherein the polymer having a plurality of oxazolinyl groups comprises an acrylic polymer. 
     
     
         14 . The method of  claim 11 , wherein the polymer having a plurality of oxazolinyl groups is at least 1 part per hundred parts of resin (PHR). 
     
     
         15 . The method of  claim 11 , wherein the curable prebond precursor composition comprises a polymer having a plurality of oxazolinyl groups and a polyurethane having a plurality of carboxyl groups, wherein, on a solids basis, the polymer having a plurality of oxazolinyl groups and the polyurethane are present in a weight ratio of from 1:99 to 8:92. 
     
     
         16 . (canceled) 
     
     
         17 . The method of  claim 11 , further comprising:
 disposing a curable size layer precursor composition on the at least partially cured make layer composition; and   at least partially curing the curable size layer precursor composition.   
     
     
         18 . The method of  claim 11 , wherein the nonwoven abrasive article comprises a nonwoven abrasive disc. 
     
     
         19 . The method of  claim 11 , wherein the lofty open nonwoven fiber web comprises polyamide. 
     
     
         20 . The method of  claim 11 , wherein disposing and securing the abrasive layer on at least a portion of the prebond composition comprises:
 disposing an abrasive layer precursor composition onto at least a portion of the prebond composition, wherein the abrasive layer precursor composition comprises phenolic resin and abrasive particles;   wherein at least one of the curable prebond precursor composition and the abrasive layer precursor composition comprises a polymer having a plurality of oxazolinyl groups;   and at least partially curing the abrasive layer precursor composition.   
     
     
         21 . The method of  claim 11 , wherein the abrasive layer precursor composition or the curable make layer precursor composition comprises the polymer having a plurality of oxazolinyl groups, wherein the polymer having a plurality of oxazolinyl groups is at an amount of at least 1 part per hundred parts of resin (PHR). 
     
     
         22 . The method of  claim 11 , wherein the polymer having a plurality of oxazolinyl groups is water-based.