阅读说明：本技术 独立式抛光制品 (Free standing polishing article ) 是由 罗比内特·S·阿尔克哈斯 罗纳德·D·阿普尔 于 2019-07-18 设计创作，主要内容包括：本发明公开了磨料制品,该磨料制品包括纤维非织造织物、织造织物以及它们的组合的至少一个层。织物或织物的组合可具有硬化的粘附涂层。粘附涂层可包括第一涂层和第二涂层。第二涂层可形成于第一涂层的顶部上。第一涂层可包含交联的粘结剂,并且第二涂层可包含磨料颗粒和润滑剂。(Abrasive articles comprising at least one layer of fibrous nonwoven fabric, woven fabric, and combinations thereof are disclosed. The fabric or combination of fabrics may have a hardened adherent coating. The adhesive coating may include a first coating and a second coating. The second coating may be formed on top of the first coating. The first coating may comprise a cross-linked binder and the second coating may comprise abrasive particles and a lubricant.)

1. A unitized grinding wheel comprising;

at least one fibrous nonwoven layer; the nonwoven fabric has a hardened adherent coating comprising a first coating and a second coating, the second coating formed on top of the first coating;

wherein the first coating comprises a crosslinked binder; and is

Wherein the second coating comprises abrasive particles and a lubricant, wherein the abrasive particles are less than about 15 μ.

2. The unitized abrasive wheel of claim 1, wherein said abrasive particles are less than about 10 μ.

3. The unitized abrasive wheel of claim 1, wherein said nonwoven fabric comprises a combination of synthetic and natural fibers.

4. The set of wheels of claim 3, wherein the synthetic fibers comprise nylon and the natural fibers comprise cellulose.

5. The set of wheels of claim 1, wherein the nonwoven fabric comprises natural fibers.

6. The set of wheels of claim 3, wherein the natural fibers comprise cellulose.

7. The set of wheels of claim 3, wherein the natural fibers comprise 0 to 100 weight percent of the fibers.

8. The set of wheels of claim 3, wherein the natural fibers comprise 20 to 100 weight percent of the fibers.

9. The set of wheels of claim 1, wherein the crosslinked binder comprises a thermoset binder.

10. The wheel set according to claim 1, wherein the cross-linked binder is selected from the group comprising polyurea, polyurethane, epoxy, acrylic, styrene-butadiene and phenolic.

11. The wheel set of claim 10, wherein the cross-linked binder comprises a polyurethane and an amine.

12. The set of wheels of claim 1, wherein the crosslinked binder comprises 10 to 50 weight percent of the total fiber weight.

13. The set of wheels according to any one of claims 1 to 12, wherein not all of the abrasive particles are fixed to a nonwoven web.

14. The wheel set of claim 1, wherein substantially all of the abrasive particles are fixed to the nonwoven web.

15. The set of wheels of claim 1, wherein the first coating comprises abrasive particles.

16. The set of wheels of claim 4, wherein the lubricant comprises a blend of at least fatty acids, mineral oil, and glycerin.

17. The set of wheels of claim 16, wherein the fatty acid comprises stearic acid.

18. The set of wheels of claim 1, wherein a majority of the fibers are 15 denier or less in size.

19. A method of making a sleeved abrasive wheel, the method comprising the steps of:

providing a nonwoven fabric;

coating the nonwoven fabric with a first coating layer comprising a precursor crosslinking agent;

hardening the first coating to form an adhesive coated web;

compressing the adhesive coated web to form a compressed adhesive coated web; and

coating at least one outer surface of the adhesive coated web with a second coating comprising a lubricant and abrasive particles, wherein the abrasive particles are less than about 15 μ.

20. The method of claim 19, wherein the abrasive particles are less than about 10 μ.

21. The method of claim 19, wherein the second coating is applied after the first coating is hardened.

22. The method of claim 19, wherein the nonwoven fabric comprises a combination of synthetic fibers and natural fibers.

23. The method of claim 22, wherein the natural fibers comprise about 0% to 100% by weight of the weight percentage of fibers.

24. The method of any one of claims 22, wherein the natural fibers comprise 20 to 80 weight percent of the fibers.

25. The method of claim 22, wherein the cross-linked binder is selected from the group consisting of polyurea, epoxy, acrylic, and phenolic precursors.

26. The method of claim 25, wherein the crosslinked binder is polyurea.

27. The method of claim 26, wherein the cross-linked binder comprises polyurethane.

28. The method of claim 19, wherein the crosslinked binder comprises a thermoset binder.

29. The method of claim 19, wherein not all of the abrasive particles are fixed to a nonwoven web.

30. The method of claim 19, wherein substantially all of the abrasive particles are fixed to the nonwoven web.

31. The method of claim 19, wherein the first coating comprises abrasive particles.

32. The method of claim 22, wherein the lubricant comprises a blend of at least fatty acids, mineral oil, and glycerin.

33. The method of claim 19, wherein a majority of the fibers have a size of 15 denier or less.

34. A method of imparting a mirror-like finish to a metal, the method comprising the steps of:

providing a set of wheels, the set of wheels comprising;

at least one fibrous nonwoven layer; the nonwoven fabric has a hardened adherent coating comprising a first coating and a second coating, the second coating formed on top of the first coating; wherein the first coating comprises a crosslinked binder; wherein the second coating comprises abrasive particles and a lubricant, wherein the abrasive particles are less than about 15 μ; and

polishing the surface of the metal for a sufficient time to impart a desired gloss to the surface of the metal.

35. The method of claim 34, wherein the particle size is less than about 10 μ.

36. The method of claim 33, wherein the fibrous nonwoven fabric comprises synthetic fibers and natural fibers.

37. The method of claim 36, wherein the synthetic fibers comprise nylon and the natural fibers comprise lyocell.

38. The method of claim 37, wherein the natural fibers comprise from about 20 wt% to about 80 wt% of the weight percentage of the fibers.

39. The method of claim 37, wherein the cross-linked binder is selected from the group consisting of polyurea, epoxy, acrylic, and phenolic precursors.

40. The method of claim 34, wherein the crosslinked binder comprises polyurea.

41. The method of claim 40, wherein the cross-linked binder comprises polyurethane.

42. The method of claim 34, wherein the crosslinked binder comprises a thermoset binder.

43. The method of claim 34, wherein the first coating comprises abrasive particles.

44. The method of claim 37, wherein the lubricant comprises a blend of at least fatty acids, mineral oil, and glycerin.

45. A free-standing fiber polishing article comprising;

at least one layer of a combination of at least one fibrous nonwoven fabric and at least one woven fabric; the combination has a hardened adherent coating comprising a crosslinked binder, a lubricant, and abrasive particles, wherein the abrasive particles are less than about 15 μ.

46. The free-standing fiber polisher according to claim 45 wherein the abrasive particles are less than about 10 μ.

47. The free standing fiber polisher of claim 45 with a nonwoven to woven ratio in the range of about 0.5 to about 15.

48. The free-standing polishing article of claim 45, wherein the ratio of non-woven fabric to woven fabric is in the range of about 0.5 to about 13.

49. The free-standing polishing article of claim 45 or 46, wherein the ratio of nonwoven to the weave is about 1.5.

50. The free-standing polishing article of claim 45, wherein the woven fabric comprises cellulose.

51. The free-standing polishing article of claim 45, wherein the lubricant comprises at least a fatty acid, a mineral oil, and glycerin.

52. The free-standing polishing article of claim 45, wherein the woven fabric and the nonwoven fabric are mechanically entangled.

53. A method of forming a free-standing polishing wheel set, the method comprising the steps of;

providing a nonwoven fabric;

coating the nonwoven fabric with a first coating layer comprising a precursor crosslinking agent;

hardening the nonwoven fabric having the first coating layer to form an adhesive coated web to produce a web;

cutting the adhesive coated web into a desired shape;

coating at least one outer surface of the adhesive coated web with a second coating comprising a lubricant and abrasive particles; and

compressing the cut adhesive coated web to form a free-standing set of buffs.

54. The method of claim 53, wherein the abrasive particles are less than 15 μ.

55. The method of claim 53, wherein the nonwoven fabric comprises a combination of synthetic and natural fibers.

56. The method of any one of claims 55, wherein the synthetic fibers comprise nylon and the natural fibers comprise cellulose.

57. The method of any one of claims 55, wherein the lubricant comprises at least a fatty acid, a mineral oil, and glycerin.

58. The method of any one of claim 53, wherein the crosslinked binder is selected from the group consisting of polyureas, epoxies, acrylics, and phenolic precursors.

59. The method of claim 58, wherein the crosslinked binder is a polyurea.

60. The method of claim 59, wherein the crosslinked binder comprises polyurethane.

61. The method of claim 53, wherein the crosslinked binder comprises a thermoset binder.

Background

Polishers are most commonly used to finish surfaces by a three-part grinding mechanism. Driven polishers transfer energy to the workpiece, but the abrading action is provided by an abrasive composition "polish" that is applied peripherally to, rather than bonded to, the surface of the polisher. The unbonded abrasive, which is located between the workpiece and the surface of the polisher, refines the workpiece surface, resulting in fewer and smaller scratches on the workpiece surface as polishing continues. Conversely, polishing (typically a two-part lapping mechanism) is too aggressive to achieve the fineness required to produce a mirror-like finish. Accordingly, three-body lapping mechanisms have been employed to achieve mirror-like finishes.

Disclosure of Invention

The present invention relates in part to a unitized abrasive wheel comprising at least one fibrous nonwoven fabric layer; the nonwoven fabric has a hardened adherent coating comprising a first coating and a second coating, the second coating formed on top of the first coating, wherein the first coating comprises a crosslinked binder, and wherein the second coating comprises abrasive particles and a lubricant, wherein the abrasive particles are less than about 15 μ.

Other aspects of the invention relate, in part, to a method of making a dressed grinding wheel comprising the steps of: providing a nonwoven fabric; coating a nonwoven fabric with a first coating layer, the first coating layer comprising a precursor crosslinking agent; hardening the first coating to form an adhesive coated web; compressing the adhesive coated web to form a compressed adhesive coated web; and coating at least one outer surface of the adhesive coated web with a second coating comprising a lubricant and abrasive particles, wherein the abrasive particles are less than about 15 μ.

Other aspects of the invention are directed, in part, to a method of imparting a mirror-like finish to a metal, the method comprising the steps of; providing a wheel set comprising at least one fibrous nonwoven layer; the nonwoven fabric has a hardened adherent coating comprising a first coating and a second coating, the second coating formed on top of the first coating, wherein the first coating comprises a crosslinked binder, wherein the second coating comprises abrasive particles and a lubricant, wherein the abrasive particles are less than about 15 μ; and polishing the surface of the metal for a sufficient time to impart the desired gloss to the surface of the metal.

Other aspects of the invention relate, in part, to a free-standing fiber polishing article comprising at least one layer of a combination of at least one fibrous nonwoven fabric and at least one woven fabric; the combination has a hardened adherent coating comprising a cross-linked binder, a lubricant, and abrasive particles, wherein the abrasive particles are less than about 15 μ.

Other aspects of the invention are directed, in part, to a method of forming a free-standing polishing wheel set, the method comprising the steps of: providing a nonwoven fabric; coating a nonwoven fabric with a first coating layer, the first coating layer comprising a precursor crosslinking agent; hardening the nonwoven fabric having the first coating to form an adhesive coated web to produce a web; cutting the adhesive coated web into a desired shape; coating at least one outer surface of the adhesive coated web with a second coating comprising a lubricant and abrasive particles; and compressing the cut adhesive coated web to form a free-standing set of buffs.

Drawings

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure, which broader aspects are embodied in the exemplary construction. The figures are for illustration only and should not be used to scale the actual dimensions of the nonwoven abrasive web or the resulting nonwoven abrasive article.

Fig. 1A shows a perspective view of a nonwoven abrasive web.

Fig. 1B shows an enlarged view of the nonwoven abrasive web of fig. 1 a.

Figure 2 shows a perspective view of an embodiment of a set of wheels according to the invention.

Fig. 3 shows a perspective view of an embodiment of a swivel wheel according to the present invention.

Figure 4 shows a perspective view of an embodiment of a polishing wheel according to the present invention.

Figure 5 shows a perspective view of an embodiment of a polishing wheel according to the present invention.

Figure 6 shows a perspective view of an embodiment of a polishing wheel according to the present invention.

FIG. 7 shows a perspective view of an embodiment of a foil brush according to the present invention.

Fig. 8 shows a perspective view of an embodiment of a tab belt according to the invention.

Fig. 9 shows a flow chart of a method according to the invention.

Definition of

As used herein, "free-standing fiber polishing article" means a polishing article that includes a pre-applied or pre-impregnated abrasive polishing composition to a fiber material, thereby forming a polishing article. The abrasive polishing composition is suitable for cutting or color polishing and is applied to the polishing article by the manufacturer during initial manufacture of the polishing article. Thus, there is no need for an operator to apply a polishing agent to the polishing article prior to or at the time of first using the polishing article to polish a work surface.

As used herein, "hardening," when used to describe solidification of a precursor, refers to curing (e.g., polymerization and/or crosslinking by heat or otherwise), drying (e.g., driving off volatile solvents), and/or simply by cooling.

As used herein, the forms of the words "comprising," "having," and "including" are legally equivalent and open-ended. Thus, additional non-recited elements, functions, steps or limitations may be present in addition to the recited elements, functions, steps or limitations.

Detailed Description

While triple body abrasive systems produce a mirror finish, a disadvantage is that polishing agents that must be frequently applied to achieve a consistent finish may undesirably transfer to adjacent surfaces. The resulting residue must then be removed. Attempts to address these deficiencies by employing a two-piece abrasive system, in which the abrasive composition is hardened to the working surface of the polisher or pre-impregnated rather than peripherally applied, have not been successful for cutting and color polishing. Accordingly, cutting and/or color polishing requires having a pre-impregnated abrasive composition for polishing such that the need to apply a polishing agent to the polishing wheel is substantially eliminated.

Certain embodiments of the free-standing fiber polishing article are formed as a set of wheels or a convolute wheel and comprise at least one fibrous nonwoven layer impregnated with a pre-bond coating comprising at least a first cross-linkable binder precursor and at least a second coating comprising abrasive particles, a lubricant, and optionally a second cross-linkable binder precursor. The pre-bond coating and the second coating form an adherent coating comprising a pre-impregnated abrasive polishing composition. In other embodiments, additional coatings may be applied that aid in the adhesion coating of the polishing article.

Certain embodiments of the free-standing fibrous article are formed into a polishing wheel. The polishing wheel includes a combination of woven and non-woven fabrics. The combination of fabrics is impregnated with at least one coating comprising at least a first cross-linkable binder precursor, an abrasive, and a lubricant. In other embodiments, additional coatings may be applied that aid in the adhesion coating of the polishing article.

Nonwoven fabric

Nonwoven fabrics useful in the practice of the present invention can be made by any known web forming system. In some embodiments, the fabric may be spunbond, spunlaced, or meltblown. In some embodiments, the nonwoven fabric is a dry-laid nonwoven fabric. In some embodiments, the nonwoven fabric is an air laid nonwoven fabric. In some embodiments, the nonwoven fabric is formed by carding and cross-lapping. While web forming processes using staple fibers are typical, continuous filament systems, such as spunbond or meltblown, may also be used. Useful staple fiber lengths include lengths between 0.05 inch (12.7mm) and 4 inches (102mm), inclusive. In some embodiments, a pre-bond coating may be applied to enhance the integrity of the nonwoven fabric.

The fibrous component of the nonwoven fabric may be of synthetic, man-made or natural origin. Exemplary synthetic fibers are polyesters such as poly (ethylene terephthalate) or poly (butylene terephthalate), polyamides such as poly (hexamethylene adipate) or polycaprolactam, polyolefins such as polyethylene or polypropylene, and melt fibers. Exemplary rayon fibers include cellulose acetate, rayon, and lyocell. In some embodiments, natural fibers such as cotton, jute, ramie, and wool may be used alone or in combination. In some embodiments, blends of two, three, or even more fiber components may be used.

In some embodiments, the fibers may have a denier of 0.1 (0.11 dtex) or greater. In some embodiments, the fiber size may be 20 denier (22.5 dtex) or less, 15 denier or less, 6 denier or less, or 3 denier or less. In some embodiments, a mixture of titers or ranges of two or more fibers may be used. In some embodiments, the majority, 70%, 80%, 90%, or 95% of the fibers forming the nonwoven are selected to have a fiber size of 0.1 denier to 20 denier, 15 denier, 6 denier, or 3 denier.

In some embodiments, the nonwoven fabric comprises cellulosic fibers. In some embodiments, the nonwoven fabric is at least 30% by weight cellulosic fibers, or at least 50% by weight cellulosic fibers, or at least 70% by weight, up to 100% cellulosic fibers. Other natural, synthetic or synthetic fibers may also be incorporated, including polyamides (e.g., nylon 6,6), polyesters (e.g., polyethylene terephthalate, polybutylene terephthalate), rayon, cellulose acetate or cotton. In some embodiments, the nonwoven fabric may comprise melt-bondable fibers, including melt-bondable fibers that may be crosslinked after melt-bonding to render them thermoset.

The nonwoven fabric was prepared to have a weight of 50g/m²To 500g/m²Or 75g/m²To 400g/m²Or 100g/m²To 300g/m²Basis weight of (c). The thickness of the nonwoven fabric is typically from 1mm to 20mm, or from 1mm to 15mm, or from 2mm to 5 mm. In some embodiments, the nonwoven fabric is subsequently needle-stitched. In other embodiments, the nonwoven fabric may be subsequently calendered and/or otherwise heat treated (e.g., through-bonding).

Woven fabric

Suitable woven fabrics may be selected from those made from synthetic or natural fibers or combinations thereof. Examples of synthetic fibers include polyester, nylon, and rayon. Examples of natural fibers include cotton, jute, hemp, bamboo, and silk. Various characteristics of the woven fabric, such as, for example, fiber composition, denier size, and number of weft and warp yarns, may be adjusted to provide a fabric having desired characteristics known to those skilled in the art. For example, the needle count may be adjusted to produce a stiffer or more flexible fabric suitable for a particular application.

In some embodiments, the woven fabric is selected such that it imparts durability without damaging or scratching the surface it is polishing. In some embodiments, the woven fabric comprises a scrim. In one embodiment, the woven fabric comprises a cotton fabric, such as J-Cloth from Indreft Textile Mills, India.

Pre-bond coating

The pre-bond coating comprises a first cross-linkable binder precursor. Suitable first crosslinkable binders are discussed below, but a preferred crosslinkable binder is polyurethane. Useful pre-bond coatings are formulated to maximize desired web properties (tear, stretch, flexibility) and to provide desired end product properties (e.g., cut, abrasion, finish) during use. Useful compositions of the pre-bond coating include 3 wt% to 85 wt%, 30 wt% to 85 wt%, 51 wt% to 85 wt%, and 70 wt% to 85 wt% of the binder precursor. The coating may be applied by any conventional means, such as, for example, roll coating, spray coating, or saturated coating. In some embodiments, the pre-bond coating may further comprise abrasive particles, lubricants, and/or optional additives.

Second coating layer

The second coating comprises a dispersion of abrasive particles, a lubricant, and optionally a second cross-linkable binder precursor. Useful secondary coatings are formulated to maximize the desired abrasive effect (cutting or buffing), to maximize the flexibility of the polisher, and to minimize both smearing (undesirable transfer of polishing components to the workpiece) and dust during use. Useful compositions of the second coating are 0 wt% to 50 wt% binder precursor, 5 wt% to 99 wt% lubricant, and 0 wt% to 80 wt% mineral. In one or more coating steps, the nonwoven fabric is coated with a secondary coating and other optional additives. The coating may be applied by any conventional means, such as, for example, roll coating, spray coating, or saturated coating. In some embodiments, three coatings are applied: a lubricant coating followed by a hardening step; a phenolic resin coating, followed by a hardening step; and a lubricant coating, followed by a hardening step. In some embodiments, the coating is applied in at least two separate steps, wherein the binder precursor and mineral are applied and then hardened, followed by lubricant coating and hardening. In further embodiments, two lubricant coatings are applied and hardened.

Single coating

The single coat comprises a dispersion of a cross-linkable binder precursor, abrasive particles, and a lubricant. The single coating layer may optionally comprise a second binder precursor and/or other additional other additives. The single coat is formulated to produce an abrasive article that avoids the prebond coating process. The single coating that is useful is formulated to maximize the desired abrasive effect (cutting or buffing), to maximize the flexibility of the polisher, and to minimize both smearing (undesirable transfer of polishing components to the workpiece) and dust during use. The useful composition of the single coating is 0-50 wt% binder precursor, 5-80 wt% lubricant, and 0-70 wt% mineral. In one or more coating steps, the nonwoven fabric may be coated with additional coatings and/or other optional additives. The coating may be applied by any conventional means, such as, for example, roll coating, spray coating, or saturated coating.

Cross-linkable binder precursor

Suitable binder precursors for the first and second crosslinkable binders include urethane resins such as polyurethane polymers or prepolymers, epoxy resins, phenolic resins, acrylic resins, urea-formaldehyde resins, melamine-formaldehyde resins, styrene-acrylic resins, styrene-butadiene, and combinations thereof. In some embodiments, the first and second crosslinkable binders are selected to be different chemistries, such as phenolic and acrylic resins. In other embodiments, the first and second crosslinkable binders are the same chemistry, but may be applied at the same or different coating weights.

Examples of useful urethane prepolymers include polyisocyanates and their blocked forms. Typically, blocked polyisocyanates are substantially unreactive with isocyanate-reactive compounds (e.g., amines, alcohols, thiols, etc.) under ambient conditions (e.g., temperatures in the range of about 20 ℃ to about 25 ℃), but upon application of sufficient thermal energy the blocking agent is released, thereby generating isocyanate functional groups that react with the amine curing agent to form covalent bonds.

Useful polyisocyanates include, for example, aliphatic polyisocyanates (e.g., hexamethylene diisocyanate or trimethylhexamethylene diisocyanate); alicyclic polyisocyanates (e.g., hydrogenated xylylene diisocyanate or isophorone diisocyanate); aromatic polyisocyanates (e.g., tolylene diisocyanate or 4,4' -diphenylmethane diisocyanate); adducts of any of the above polyisocyanates with polyols (e.g., diols, low molecular weight hydroxyl group-containing polyester resins, water, etc.); adducts of the above polyisocyanates (e.g., isocyanurates, biurets); and mixtures thereof.

Useful commercially available polyisocyanates include, for example, those available under the trade designation "ADIPRENE" (e.g., "ADIPRENE L0311", "ADIPRENE L100", "ADIPRENE L167", "ADIPRENE L213", "ADIPRENE L315", "ADIPRENE L680", "ADIPRENE LF 1800A", "ADIPRENE LF 600D", "ADIPRENE LFP 1950A", "ADIPRENE LFP 2950A", "ADIPRENE LFP 590D", "ADIPRENE LW 520" and "ADIPRENE PP 1095") from Chemtura Corporation, Middlebury, Conn.,; polyisocyanates available under the trade designation "MONDUR" (e.g., "MONDUR 1437", "MONDUR MP-095" or "MONDUR 448") from Bayer Corporation, Pittsburgh, Pa; and polyisocyanates available from Air Products and Chemicals, Allentown, Pa., of Allentown, Pa., Inc. of Allentown, Pa., USA, under the trade names "AIRTHANE" and "VERSATHANE" (e.g., "AIRTHANE APC-504", "AIRTHANE PST-95A", "AIRTHANE PST-85A", "AIRTHANE PET-91A", "AIRTHANE PET-75D", "VERSATHANE STE-95A", "VERSATHANE STE-P95", "VERSATHANE STS-55", "VERSATHANE SME-90A", and "VERSATHANE MS-90A").

To extend pot life, polyisocyanates (such as, for example, those mentioned above) can be blocked with blocking agents according to various techniques known in the art. Exemplary blocking agents include ketoximes (e.g., 2-butanone oxime); lactams (e.g., epsilon-caprolactam); malonic acid esters (e.g., dimethyl malonate and diethyl malonate); pyrazoles (e.g., 3, 5-dimethylpyrazole); alcohols including tertiary alcohols (e.g., t-butanol or 2, 2-dimethylpentanol), phenols (e.g., alkylated phenols), and mixtures of the foregoing alcohols.

Exemplary useful commercially available blocked polyisocyanates include those sold by Chemtura Corporation under the trade designations "ADIPRENE BL 11", "ADIPRENE BL 16", "ADIPRENE BL 31", and blocked polyisocyanates sold by basxinden Chemicals, ltd, Accrington, England under the trade designation "triene" (e.g., "triene BL 7641", "triene BL 7642", "triene BL 7772", and "triene BL 7774").

Suitable amine curing agents include aromatic, alkyl-aromatic or alkyl polyfunctional amines, preferably primary amines. Examples of useful amine curing agents include 4,4' -methylenedianiline; polymeric methylene dianilines having a functionality of 2.1 to 4.0, including those known under the trade designation "CURITHANE 103" commercially available from Dow Chemical Company, and those under the trade designation "MDA-85" commercially available from Bayer Corporation, Pittsburgh, Pa., Pittsburgh, Pennsylvania; 1, 5-diamine-2-methylpentane; tris (2-aminoethyl) amine; 3-aminomethyl-3, 5, 5-trimethylcyclohexylamine (i.e., isophoronediamine), trimethylene glycol di-p-aminobenzoate, bis (o-aminophenylthio) ethane, 4' -methylenebis (dimethyl anthranilate), bis (4-amino-3-ethylphenyl) methane (e.g., as sold under the trade name "KAYAHARD AA" by Nippon Kayaku Company, ltd., Tokyo, Japan); unmodified aromatic amine curing agents, including 3,3 'diethyl 4,4' diaminodiphenylmethane, are believed to be sold under the trade designation "LAPOX K-450" by reus International, royle International, East Rutherford, New Jersey; and bis (4-amino-3, 5-diethylphenyl) methane (e.g., as sold under the trade designation "LONZACURE M-DEA" by losza, ltd., Basel, Switzerland) and mixtures thereof. If desired, for example, a polyol can be added to the hardenable composition to modify (e.g., delay) the cure rate as required by the intended use.

The amine curing agent must be present in an amount (i.e., an effective amount) to enable it to function to cure the blocked polyisocyanate to the extent required for the intended application; for example, the amine curing agent may be present in a stoichiometric ratio in the range of 0.8 to 1.05 or in the range of 0.85 to 1.0.

Phenolic materials are useful binder precursors due to their thermal characteristics, availability, cost and ease of handling. The resole phenolic resin has a formaldehyde to phenol molar ratio of greater than or equal to 1, typically from 1.5:1.0 to 3.0: 1.0. The novolac phenolic resin has a formaldehyde to phenol molar ratio of less than 1.0: 1.0. Examples of commercially available phenolic resins include those identified by the trade names DUREZ and VARCUM (available from western Chemicals Corp.), the trade name RESINOX (available from Monsanto), the trade name arofen (available from Ashland Chemical Co.), and the trade name AROTAP (available from Ashland Chemical Co.).

In some embodiments, the amount of phenolic binder precursor present in the phenolic binder coating is in an amount of 2 to 50 weight percent, or 5 to 40 weight percent, or even 5 to 35 weight percent, based on the total weight of the coating composition, although amounts outside of these ranges may also be used.

Emulsions of crosslinked acrylic resin particles may also be used in the present invention.

Some binder precursors include a phenolic resin mixed with latex. Examples of such latexes include materials comprising acrylonitrile butadiene, acrylics, butadiene-styrene, and combinations thereof. These latexes are commercially available from a variety of sources and include those commercially available under the tradenames rhoflex and ACRYLSOL from Rohm and Haas Company, flexroyl and VALTAC from Ashland Corporation (Ashland Inc.), synthol, TYCRYL and TYLAC from Mallard Creek Polymers Inc, Lubrizol Corporation under the tradenames hycaryl, gordonl and tylate, goodrick Corporation (b.f. goodrich), cheigum from goodish Corporation (goodrich), Goodyear Tire and Rubber Company (Goodyear and Rubber Co.), noochrigum Corporation under the tradename george ICI, bubal Corporation (ICI), bubal latex from united Carbide under the tradename taylon, and Carbide.

Lubricant agent

Examples of lubricants for free-standing fiber polishing articles include fatty acids (e.g., stearic, lauric, palmitic, myristic, oleic, palmitoleic, linoleic, and linolenic), metal salts of fatty acids (e.g., lithium stearate, zinc stearate), solid lubricants (e.g., poly (tetrafluoroethylene) (PTFE), graphite, and molybdenum disulfide), mineral oils and waxes (including micronized waxes), carboxylic acid esters (e.g., butyl stearate), poly (dimethylsiloxane) fluids, poly (dimethylsiloxane) gums, and simple polyol compounds such as glycerol, and combinations thereof. Such lubricants and commercial sources are known in the art. Other suitable lubricants may be apparent to those skilled in the art upon reading this disclosure.

Useful lubricants include, for example, stearic acid (obtained from Acme Hardesty Oliochemics, Blue Bell, Pennsylvania, Inc.), "INDUSTRENE 4516" (obtained from PCM Biogenics, Memphis, Tennese, of Mengifer, Tennessee), lithium stearate (obtained from Ashland, Inc., Covington, Kentucky), zinc stearate "ZINCSW", "ZINCUM AV", calcium stearate "CEASSW", and "CEASAV" (obtained from Brazilian division of California, Baerlocher Do scientific S.A, America, SP, Braziel), "COMAX A", "COMAX TAX DA" and IPAX QuipaDA (obtained from Brazilian Quifi, Coxil Q & A, Quifi), and "IPica" (obtained from Brazilian Quifi Quika, Coxil Quifila, Coxil), which is obtained from Brazilian Hardest Oleochem Oleochemics, Quinal 4516, Inc. (obtained from Pythis, Melicica, Zernica, Tenuical, Quinal, and A "(obtained from Brazilian, Zernica, Quinal, and a, obtain a, Zernica, a LTDA, italeccica, MG, Brazil)), "MP-22 wax" (available from micro powder company, inc. of talindon, NY), "Drakeol mineral oil-USP grade" (available from Penreco, Karns City, PA), KAYDOL paraffin oil (available from Sonneborn, Mahwah, NJ), mineral oil (available from united states corporation of united states of america, Redmond, wangton), and glycerin (available from asme hardest Oleochemicals, Blue Bell, Pennsylvania).

Abrasive particles

Suitable abrasive particles are those that can be used in polishing operations. The abrasive particles may have any suitable composition, but those comprising chromium oxide, titanium oxide, aluminum oxide, calcined micronized aluminum oxide, iron oxide, or silicon carbide are typical. Suitable abrasive particle size distributions include those having a median particle diameter of less than 15 microns or less than 10 microns.

Examples of useful abrasive particles include "E2616 GREEN" (available from Akrochem chemical company of Akrochem, Akron, Ohio), "KRONOS 2310" (available from cornos inc, Houston, Texas), iron oxide "BK-5099" I (available from Elementis Pigments inc, Fairview Heights, iloils), or "microsoft WCA," or microsparent DD (available from microabrader Corporation of weber philippinard, samearland, inc.), precipitated silica (available from kimarovea, kishinou), precipitated silica (available from kikupiai industrial hydrotalcite of pashia, inc., dhjokumura, dhjonam, inc.), precipitated silica (available from kikupiantan aluminum oxide, dhjonshi, dhjones, inc), edison, NJ)), and combinations thereof.

In some embodiments, the abrasive particles may be larger, depending on the needs of the application. The present invention contemplates the use of any suitable abrasive. The abrasive may be selected by various factors known to those skilled in the art.

Other optional additives

Other optional additives that may facilitate the formation of a secondary or other coating of the adherent coating include surfactants, wetting agents, defoamers, colorants, coating modifiers, and coupling agents.

The anionic surfactant facilitates the incorporation of the lubricant into the second coating. An example of a useful anionic surfactant is sodium dioctyl sulfosuccinate available under the trade designation "Aerosol OT-75" (available from Cytec Do Brasil Ltd., Sao Paulo, SP, Brazil) from Cytec Do Brasil Ltd., Brazil, Calif.). Another useful emulsifier is triethanolamine, such as that available under the trade designation "triethanolamine 99% TECH" (available from Ashland Chemical Company, Columbus, OH) from columbia Chemical Company of columbia, ohio).

Wetting agents can be used to facilitate impregnation of the fiber polishing material with the coating. Useful wetting agents include at least partially non-ionic surfactants such as "NopcoWet BR" (available from Gap quiimica ltda, guaroulhos, SP, Brazil) available from guar quiimica ltda, santa pau. Other useful nonionic surfactants include "TERGITOL 15-S-40" and "TERGITOL XJ" (both from Dow Chemical, Midland, Michigan) and "PEG DS 6000" (from BASF, Florham Park, N.J.).

Coating modifiers and VOC reducing agents such as hydroxyethylethylene urea can be used to promote film formation. Useful coating modifiers include "SR-511" (obtained from Sartomer Company, Exton, Pennsylvania) from Sartomer, Pa. Other coating modifiers and pH adjusters (such as citric acid) can be used to control the coating viscosity.

Coupling agents can be used to improve the adhesion between the nonwoven polishing material, the binder, and the abrasive mineral. Useful coupling agents include "Z-6020 silane" and "Z-6040 silane", both available from Dow Corning, Midland, Michigan, Mich.

Colorants or pigments such as iron oxide, titanium oxide, or carbon black may be added to visually identify different polishing articles and/or types of polishing articles. In some embodiments, pigments such as chromium oxide may also be used as abrasive particles. Suitable colorant Pigments include "KRONOS 2310" (cornos inc. of Houston, Texas), "E2616 GREEN" (Akrochem chemical Corporation, Akron, Ohio), "BK-5099 pigment" (elements Pigments inc. of fel veu joh, Illinois) and "copperes Red Iron Oxide R5098D" (elements Pigments inc. of fel veu joh, Illinois).

Coating impregnation process

Free-standing fiber polishing articles are prepared by impregnating a length of a suitable fibrous nonwoven fabric with a pre-bond coating, followed by thermal lamination and/or stiffening. The pre-bond coating may be applied by conventional application means such as roll coating, curtain coating, die coating or spray coating.

A second coating comprising abrasive particles, a lubricant, and optionally a second cross-linkable binder precursor, and a wetting agent and/or surfactant can be applied over the pre-bond coating and subsequently hardened to form a hardened second coating on the fibers and surfaces of the nonwoven fabric. The adhesive coating may be incorporated into the fibrous material in one or more steps with one or more hardening steps as described previously. In some embodiments, a second coating is incorporated and hardened, followed by the incorporation of a subsequent coating comprising additional lubricant, and then an additional hardening step. The adhesive coating may be applied by conventional application means such as roll coating, curtain coating, die coating or spray coating.

In some embodiments, both the pre-bond coating and the second coating comprise abrasive particles. The particles in the pre-bond coat may have the same or different composition, size and number (absolute or weight percent based on the total weight of the coating composition). In other embodiments, the pre-bond coating and the secondary coating are combined, which is referred to as a "single coating. The single coating may comprise a lubricant, one or more cross-linking precursors, and one or more abrasives.

In some embodiments, the total added dry weight of the coating is 50g/m²To 2000g/m²Or 200g/m²To 1500g/m²Or 200g/m²To 1100g/m². In some embodiments, the total weight of the final coated polishing fabric is 200g/m²To 1500g/m²。

Free standing fiber product

The free-standing fibrous article formed according to the present invention must not only be able to withstand the harsh use conditions typically encountered in polishing operations, but must also be able to retain the adhered polishing composition on the polishing surface. The free-standing fiber polishing article can be any design or style now known or contemplated in the future. Non-limiting examples of fibrous polishing articles include polishing wheels, sets of wheels, surface finishes, airfoil brushes, and spinning wheels.

A method of making a nonwoven abrasive web according to the present invention comprises the sequential steps of: applying a pre-bond coating to the nonwoven fibrous web (e.g., by roll coating or spray coating), curing the pre-bond coating, impregnating the nonwoven fibrous web with a second coating composition (e.g., by roll coating or spray coating), and curing the curable composition. Alternatively, a single coating may be applied (e.g., by roll coating or spray coating) and cured advantageously circumvents the need for multiple coating and curing steps.

The steps described above may be performed in a different order. For example, according to some embodiments, the application of the pre-bond coating may be followed by a lamination step (instead of curing) and other processes, such as molding, cutting, or other processes that occur prior to the application of the second coating. In these embodiments, curing occurs after the article has been formed, for example, in the case of a set of wheels and convolute wheels. In other embodiments, the cutting and molding process may be performed after the second coating is cured.

Typically, the amount of curable composition coated on the nonwoven fibrous web is from 50gsm to 1500gsm, more typically from 75gsm to 800gsm, and even more typically from 100gsm to 500gsm, although values outside of these ranges may also be used.

An exemplary embodiment of a nonwoven abrasive article is shown in fig. 1a and 1b, wherein lofty open low density fibrous webs 100 formed from entangled filaments 110 are held together by a polyurethane binder 120. Abrasive particles 140 are dispersed throughout the fibrous web 100 on the exposed surfaces of the filaments 110. The polyurethane binder 120 coats portions of the filaments 110 and forms beads 150 that may encircle individual filaments or bundles of filaments, adhere to the surface of the filaments and/or gather at the intersections of contacting filaments, thereby providing abrasive sites throughout the nonwoven abrasive article.

Webs of the type described may be formed into a variety of abrasive articles. Such polishing articles can be of any design or style now known or later devised. Non-limiting examples include; spinning wheels, sets of wheels, buffing wheels, and flap brushes or belts.

The convolute abrasive wheel may be provided by: for example, a nonwoven fiber web that has been impregnated with a curable composition is wound under tension around a core member (e.g., a tubular or rod-shaped core member) such that the impregnated nonwoven fiber layers become compressed, and then the curable composition is cured, resulting in a polyurethane binder that binds the abrasive particles to the layered nonwoven fiber web and the layers of the layered nonwoven fiber web to each other. A convolute abrasive wheel 200 is shown in fig. 2, wherein a layered nonwoven fibrous web 210 is helically disposed about and secured to a core member 230, the layered nonwoven fibrous web 210 being coated with a polyurethane binder that binds abrasive particles to the layered nonwoven fibrous web and bonds the layers of the layered nonwoven fibrous web to each other. If desired, the convolute abrasive wheel can be dressed prior to use, for example, using methods known in the abrasive art, to remove surface irregularities.

The unitized abrasive wheel can be provided by: for example, the impregnated nonwoven fibrous web is layered (e.g., into a stack of layered continuous webs or sheets), the nonwoven fibrous layers are compressed, the curable composition is cured (e.g., using heat), and the resulting abrasive article is die cut to provide a unitized abrasive wheel having a central aperture. A unitized abrasive wheel 300 having a plurality of nonwoven abrasive layers 310 that have been compressed and cured is shown in fig. 3. After the abrasive layer is cured, the resulting block may be die cut to form a grinding wheel having a central aperture 320.

When compressing the impregnated layers of nonwoven fiber web in the process of making an abrasive wheel, one or more of the layers are typically compressed to form a block having a density of 1 to 10 times the density of each layer in its uncompressed state. Next, the block is typically subjected to hot molding (e.g., 1 to 60 minutes) at elevated temperature (e.g., at 135 ℃), which typically depends on the size of the urethane prepolymer and the set of blocks.

The polishing wheel may be formed from layers of fibrous material that are stacked or fastened together, for example. Fastening methods include, for example, compression, stitching, stapling, adhesive bonding, plastic or metal buckles, and combinations thereof.

The polishing wheel is typically attached to a shaft and supported for rotation. Polishers have long been used to finish articles such as machined parts, stamped parts, and cast articles, which often have surfaces that must be finished, often for aesthetic purposes. Polishing is a finishing process that is typically done after more severe cutting treatments are applied to the surface. The polisher is typically rotated to achieve a working surface speed of 1000m/min to 3500 m/min.

Fig. 4 shows a polisher 400 comprised of a layer 410 of fibrous polishing material optionally stitched with one or more sewing rings 420 having a suitable thread known for this purpose between an outer edge 430 and a central opening 440 for attachment to a rotating spindle or mandrel. The layers of fibrous polishing material have a generally circular shape and they are stacked (or the entire assembly is cut) such that the edge of each layer defines a cylindrical surface that is the peripheral edge of the polisher.

FIG. 5 shows a polisher 500 comprised of a layer of fibrous polishing material 50 stitched together with several circular stitching patterns 520 with appropriate threads. The stitching pattern may be concentric, spiral, square, radial arc, or a combination thereof. The polisher 500 has a central opening 540 for attachment to a rotating spindle or mandrel.

Fig. 6 shows a so-called "pleat" polisher 600, which is produced by the following steps: a continuous strip of fiber polishing material is cut and convolutely wound around the spaced ends of an axially aligned cylindrical mandrel, the wound strip is radially shrunk in the middle to form a flat "corrugated" annulus, and a rigid plastic or metal snap ring 620 is installed in the opening of the annulus. The "pleated" fibrous polishing material loop may also be secured by stapling, sewing, or adhesive bonding to a suitable rigid loop (such as a loop formed of cardboard).

The particular configuration of the pin-on polisher will depend on its end use. As shown in fig. 5, a polisher formed of fabric layers sewn together is generally used for cutting polishing. The very tight rows of stitches increase the stiffness of the stitch polishers to increase the cutting effect. The stitch pattern for such polishers may vary from concentric stitches, radial stitches, square stitches, spiral stitches to radial arc stitches, and radial arcs with a spiral center, depending on the needs of the user. The concentric stitches result in uneven density as the polisher wears in use. As the polisher wears closer to the traces, the polisher will become stiffer and softer just past a line of traces. Spiral stitching produces a more uniform density, but the polished surface will still have a density variation. The square and non-concentric stitch patterns create dimples that can aid in the polishing process.

Pleated or pleated polishers are popular for their excellent runnability, which is provided by the pleats or folds in their fabric. The type of construction of the plication polisher also depends on its end use. Different hardness may be required for various cutting and/or color polishing applications. The hardness can be controlled to some extent by the polishing spacing on the mandrel, but is more commonly controlled by the degree of wrinkling, the diameter of the polisher relative to the diameter of the retaining ring, or the stiffness of the polishing cloth.

Other free-standing fiber polishing articles may also have utility, including a "vane brush" configuration 700 with a single polishing vane 710, as shown in FIG. 7, or a "vane belt" configuration 800 with a single polishing vane 810, as shown in FIG. 8. Polishing articles such as needle tapes or disks may also have utility.

The present inventors have surprisingly found that incorporating a combination of woven and non-woven fabrics into a polishing wheel not only increases the durability of the wheel, but also advantageously allows the pre-bond coating step to be avoided, thereby significantly simplifying the manufacturing process. Thus, free standing buffs made according to embodiments of the present invention can be made by a simple one-pass process in which the crosslinker, abrasive, and lubricant can be applied simultaneously to the fabric to produce a durable buff.

Fig. 9 illustrates a method 900 for producing a web that can be formed into a free-standing polishing article. The operations of method 900 presented below are intended to be illustrative. In some embodiments, method 900 may be implemented with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 900 are illustrated in FIG. 9 and described below is not intended to be limiting.

Heretofore, free standing buffing wheels have been produced by methods involving multiple coating and/or curing steps. An example of a multi-step process is described in U.S. patent No. 9,08,299, the entire contents of which are hereby incorporated by reference. Multiple steps may undesirably increase production time and cost. The applicant has developed a method whereby the coating of the web can be done in a one-pass coating process, thereby significantly reducing production time and costs.

According to embodiments of the present invention, woven fabrics are incorporated into fibrous nonwoven fabrics, such as those provided in 910, 920, described previously. The combined web 90 is then coated with a dispersion comprising at least one crosslinked binder, lubricant, and abrasive particles. Such coatings are described under the sub-heading "single coat" above. The coating may be applied by any conventional means, such as, for example, roll coating, spray coating, or saturated coating, or other suitable techniques. The web so coated may be cured 940 to produce a coherent web which may then be processed accordingly to produce a free standing buffing wheel 950.

Examples of suitable woven and nonwoven fabrics are provided above. However, it should be understood that the description of such fabrics is exemplary, and the invention encompasses any suitable woven and non-woven fabrics and combinations thereof.

Examples

Various embodiments of the present invention may be better understood by reference to the following examples, which are provided by way of illustration. The present invention is not limited to the examples given herein.

The materials used in the examples are described in table 1. All parts, percentages, ratios, etc. in the examples and the remainder of the specification are by weight unless otherwise indicated.

Table 1: material。

Examples 1 to 3: production of sets of wheels。

Preparation of a complete set of pre-bonded pieces. The nonwoven web was formed on an airlaid fiber forming Machine, available from RANDO Machine Corporation, macheon, New York, under the trade designation "RANDO-WEBBER". The fibrous web was formed from a 50% blend of FIB1 and FIB2 and weighed about 84 gsm. The web was conveyed to a two roll coater where a pre-bond resin was applied. The pre-bond resin had a composition (all percentages relative to component weight) of 33.8% PMA, 1.0% LiSt, 52.7% BL16, 2.1% SD, 1.9% EB, and 8.5% AA. The prebond resin was cured to a tacky state by passing the coated web through a convection oven at 221 ° f (105 ℃) for 2 minutes, resulting in a prebond nonwoven web having a basis weight of 190 gsm. Individual sets of nonwoven abrasives were formed by stacking the prebonded nonwoven webs one on top of the other and placing in a hydraulically heated flat press set at 320 ° f (160 ℃). The release liner was placed on both sides of the stack before being placed in the oven. The uniform thickness of the blocks was maintained by placing 0.5 inch (1.27cm) thick metal shims at each corner of the platen. Pressure (15,000psi, 103.4MPa) was applied to the platen. After 10 minutes, the two portions of the web had fused together to form a single nested piece. The block was placed in a forced air oven at 275 ° f (135 ℃) for 180 minutes. After the block was removed from the oven, the block was cooled to room temperature and a unitized abrasive wheel having a diameter of 8.0 inches (20.32cm), 0.5 inches (1.27cm) thick with a 1.25 inch (3.175 cm) central bore was die cut therefrom using a SAMCO SB-25 rocker arm punch manufactured by german union shoe machines ltd (Deutsche verinitte Schuhmaschinen GmbH & co., Frankfurt, Germany), Frankfurt, Germany. The wheels were impregnated with an abrasive slurry having the formulation described in table 2. The slurry was prepared in batches at a weight of about 3 kg using a high shear mixer, and the speed was adjusted to create a strong vortex in the slurry upon mixing.

Table 2: slurry formulation。

The coated wheel set was placed in a forced air oven set at 300 ° f (149 ℃) for 8 minutes to remove the solvent. After removing the wheel from the oven, the wheel was cooled to room temperature.

Example 2: testing of sets of wheels。

The wheels were tested to measure the polishing performance of the sample wheels compared to conventional spiral stitched cotton polishers (Osborne, Hamilton, Ohio) and Green solid polishes (Osborne, Green C-3). The test was performed using a polishing apparatus manufactured by Hammond corporation (Hammond, kalamazo, Michigan) of karamatsu, Michigan. The wheel set rotates at 2100 revolutions per minute. An orthopaedic knee implant device (cobalt chrome) was pre-treated with Trizact abrasive tape 307EA Grade A16 from 3M Company (3M Company). The orthopaedic knee implant device is pushed against the face of the rotating wheel and polished to remove scratches left by the abrasive tape. Visual observations were made of the reflective or mirror-like finish left on the part, part cleanliness, working area cleanliness, and wear of the polished article. The quality of the finish is obtained by visual inspection of the presence of scratches and the level of reflectivity exhibited by the surface. Durability was obtained by visual inspection to determine the wear level of the abrasive. Component cleanliness is obtained by visual inspection to determine the amount of polishing agent residue remaining on the surface after the polishing operation. The cleanliness of the work area is obtained by visual inspection to determine the amount of debris.

Each example was compared to a conventional sewn cotton polisher and a green polish and rated as follows:

table 3: grade element

Grade	Quality of finish	Durability	Cleanliness of parts	Cleanliness of working area
					+	The smoothness quality is excellent	Excellent in durability	No visual residue	Debris reduction
＝	Equal quality of finish	Durability equivalent	Visual residual identity	Debris and the like
					-	Poor finish quality	Poor durability	Visual residue enhancement	Debris augmentation

Table 4: test results。

Wheel	Visual reflection	Wear of abrasive	Class of cleanliness of parts	Cleanliness of working area
					Example 1	＝	+	+	+
Example 2	＝	+	＝	+
					Example 3	＝	+	＝	+

Examples 4 to 12: production of polishing discs。

The nonwoven web was formed on an airlaid fiber forming Machine, available from RANDO Machine Corporation, macheon, New York, under the trade designation "RANDO-WEBBER". The fibrous web was formed from cellulosic fibers or blends of cellulosic fibers and synthetic fibers and incorporated into a woven cotton cloth as shown in table 4. In embodiments using woven cotton, the fibers are mechanically placed within the woven cloth using a needle sewing process. For the examples using thermosetting pre-bond resin, the coated web was passed through a convection oven at 300 ° f (149 ℃) for 8 minutes, resulting in a cured pre-bond. The lubricant and slurry coating are applied on top of the cured pre-bond. The lubricant and slurry coatings were cured as follows:

table 5: drying and/or curing parameters

Example #	Drying and/or curing parameters
		4. 5, 6 and 8	280 ℃ F. (138 ℃ C.) for 3 minutes
7. 9, 10, 11 and 12	300 ℃ F. (149 ℃ C.) for 8 minutes

Examples 4 to 8

The webs of examples 4-8 were formed from a blend of FIB1 and FIB2 and impregnated with a thermosetting pre-bond resin, followed by the application of a subsequent coating comprising a lubricant and an abrasive slurry.

Examples 9 to 10

Examples 9-10 were formed from a blend of FIB1 and FIB2 and incorporated into woven cotton cloth that was subsequently impregnated with a thermosetting prebond resin, followed by application of a subsequent coating comprising a lubricant and abrasive slurry and an in situ thermosetting resin.

Examples 11 to 12: examples 11-12 were formed from FIB1 and incorporated into woven cotton cloth. Notably, example 11 did not use a thermosetting pre-bond resin, and was followed by a subsequent coating containing a lubricant and an abrasive slurry, including an in-situ thermosetting resin.

Table 6: polishing disk design：

After the abrasive slurry coated web was removed from the oven, the abrasive slurry coated web was cooled to room temperature and six 4 inch (10.16cm) diameter abrasive discs with a 0.5 inch (1.27cm) center hole were die cut using a SAMCO SB-25 rocker arm punch manufactured by Deutsche verinitte Schuhmaschinen GmbH & co., Frankfurt, Germany, united shoemaking machines ltd.

Performance testing：

Six four inch (10.16cm) diameter disks were mounted on a rotary tool mounted on an X-Y table having a stationary pretreated 304 stainless steel plate measuring 10 inches (25.4 cm) long by 6 inches (15.24 cm) wide by 0.028 inches (0.071 cm) thick. Prior to performance testing, stainless steel panels were pretreated using an eccentric orbital sander from 3M Company (3M Company) at a 12,000RPM speed, run on panels for one minute using 5 inch diameter disks (12.7cm) P800 and P1200 (260L from 3M Company (3M Company)). The tool was then set to traverse an 8 inch (20.32cm) path in the + Y direction at a rate of 4.00 inches/second (10.16 cm/sec); then traverse a 0.0375 inch (0.095cm) path at a rate of 4.00 inches/second (10.16cm/sec) in the + X direction; and then traverses an 8 inch (20.32cm) path in the + Y direction at a rate of 4.00 inches/second (10.16 cm/sec). This sequence was repeated 120 times in the Y direction. The rotary tool was then activated to rotate at 2750rpm under no load. The abrasive article was then pushed radially against the stainless steel with a load of 3.5 pounds (1.59kg) with its axis of rotation parallel to the Y direction. The tool is then activated to move through the prescribed path. The mass of the discs was measured before and after each test to determine the percent total mass loss. The surface gloss in gloss units of stainless steel sheets was measured at an angle of 20 ° using "micro-TRI-gloss" from bike-Gardner GmbH, and the surface roughness was measured using "Pocket Surf PS 1" from mare (Mahr GmbH). The "Pocket Surf PS 1" transverse length was set to 5.6mm, the truncation length was set to 0.8mm, and the number of samples was set to 5. Data resulting from performance is provided in table 5.

Table 7: performance data：

Other modifications and variations of this disclosure may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of this disclosure, which is set forth in the claims. It should be understood that the various embodiments may be interchanged or combined, in whole or in part, with other aspects of the various embodiments. The preceding description, given to enable one of ordinary skill in the art to practice the claimed disclosure, is not to be construed as limiting the scope of the disclosure.