U.S. patent application number 13/230287 was filed with the patent office on 2013-03-14 for method of refurbishing vinyl composition tile.
This patent application is currently assigned to 3M INNOVATIVE PROPERTIES COMPANY. The applicant listed for this patent is Donald T. Landin, James L. McArdie. Invention is credited to Donald T. Landin, James L. McArdie.
Application Number | 20130065490 13/230287 |
Document ID | / |
Family ID | 46964014 |
Filed Date | 2013-03-14 |
United States Patent
Application |
20130065490 |
Kind Code |
A1 |
Landin; Donald T. ; et
al. |
March 14, 2013 |
METHOD OF REFURBISHING VINYL COMPOSITION TILE
Abstract
A method of refurbishing vinyl composition tile flooring
includes sequentially wet abrading an exposed surface of a vinyl
composition tile floor with a series of structured abrasive members
affixed to a machine driver pad, wherein the series of structured
abrasive members have decreasing abrasive particle size. The method
may include a prior abrading step using and aggressive nonwoven
abrasive article. The method may include application of polymeric
finish after abrading.
Inventors: |
Landin; Donald T.; (Eagan,
MN) ; McArdie; James L.; (Wilson, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Landin; Donald T.
McArdie; James L. |
Eagan
Wilson |
MN
WI |
US
US |
|
|
Assignee: |
3M INNOVATIVE PROPERTIES
COMPANY
|
Family ID: |
46964014 |
Appl. No.: |
13/230287 |
Filed: |
September 12, 2011 |
Current U.S.
Class: |
451/28 |
Current CPC
Class: |
B24D 13/14 20130101;
B24B 7/186 20130101; B24D 11/00 20130101; A47L 11/4038 20130101;
B24B 1/00 20130101 |
Class at
Publication: |
451/28 |
International
Class: |
B24B 1/00 20060101
B24B001/00 |
Claims
1. A method of refurbishing vinyl composition tile flooring, the
method comprising sequential steps: wet abrading at least a portion
of an exposed surface of a floor comprising vinyl composition tiles
with first structured abrasive members affixed to a first machine
driver pad, the first structured abrasive members comprising first
shaped abrasive composites affixed to a first compliant backing,
wherein the first shaped abrasive composites comprise first
abrasive particles dispersed in a first polymeric binder, wherein
the first abrasive particles have a first average particle size;
and b) wet abrading said at least a portion of the exposed surface
of the floor with second structured abrasive members affixed to a
second machine driver pad, the second structured abrasive members
comprising second shaped abrasive composites affixed to a second
compliant backing, wherein the second shaped abrasive composites
comprise second abrasive particles dispersed in a second polymeric
binder, wherein the second abrasive particles have a second average
particle size, and wherein the second average particle size is less
than the first average particle size; and wherein average surface
roughness R.sub.a of said at east a portion of the exposed surface
of the floor decreases during each of steps a) and b).
2. The method of claim 1, wherein average surface roughness R.sub.z
of said at least a portion of the exposed surface of the floor
decreases during each of steps a) and b).
3. The method of claim 1, wherein each of the first structured
abrasive members further comprise a first attachment interface
system secured to the first compliant backing, the first attachment
interface system having a plurality of loops opposite the first
compliant backing, wherein the first structured abrasive members
are affixed to the first machine driver pad by a first attachment
interface member having two opposed major faces having hooks
extending therefrom.
4. The method of claim 1, wherein each of the first structured
abrasive members further comprise a compliant foam layer secured to
the first compliant backing, and an attachment interface system
having a plurality of hooks opposite the compliant foam layer.
5. The method of claim 1, wherein each of the second structured
abrasive members further comprise a compliant foam layer secured to
the second compliant backing, and an attachment interface system
having a plurality of hooks opposite the compliant foam layer.
6. The method of claim 1 wherein each of the second structured
abrasive members further comprises a second attachment interface
system secured to the second compliant backing, the second
attachment interface system having a plurality of loops opposite
the second compliant backing, wherein the second structured
abrasive members arc affixed to the second machine driver pad by an
attachment interface member having two opposed major faces having
hooks extending therefrom.
7. The method of claim 6, wherein the first and second machine
driver pads are compressible and resilient.
8. The method of claim 1, wherein the first shaped abrasive
composites, the second shaped abrasive composites, or both, are
precisely-shaped.
9. The method of claim 1, wherein the s average particle size is in
a range of from 400 microns to 600 microns.
10. The method of claim 1, wherein the second average particle size
is in a range of from 25 microns to 75 microns.
11. The method of claim 1, wherein at least one of the first or
second shaped abrasive composites comprises superabrasive particles
retained in a vitreous binder.
12. The method of claim 1, wherein after step b) the average
surface roughness R.sub.a of said at least a portion of the exposed
surface of the floor is less than or equal to 95 microinches.
13. The method of claim 1, further comprising, after step b): c)
wet abrading said at least a portion of the exposed surface of the
floor with third structured abrasive members affixed to a third
compressible resilient machine driver pad, the third structured
abrasive members comprising third shaped abrasive composites
affixed to a third compliant backing, wherein the third shaped
abrasive composites comprise third abrasive particles dispersed in
a third polymeric binder, wherein the third abrasive particles have
a third average particle size, and wherein the third average
particle size is less than the second average particle size; and
wherein the average surface roughness R.sub.a of said at least a
portion of the exposed surface of the floor decreases during step
c).
14. The method of claim 13, wherein after step c), the abraded
exposed surface of the floor has an average surface roughness of
less than 80 microinches.
15. The method of claim 1, further comprising, subsequent to step
b), applying a clear polymeric finish to said at least a portion of
the exposed surface of the floor.
16. A method of refurbishing vinyl flooring, the method comprising
sequential steps: a) wet abrading at least a portion of an exposed
surface of a floor comprising vinyl composition tiles with a
nonwoven abrasive member, wherein the nonwoven abrasive member
comprises a nonwoven fiber web having first abrasive particles
adhered thereto by a first polymeric binder, wherein the first
abrasive particles have a first average particle size; b) wet
abrading said at least a portion of the exposed surface of the
floor with first structured abrasive members affixed to a first
machine driver pad, the first structured abrasive members
comprising first shaped abrasive composites affixed to a first
compliant backing, wherein the first shaped abrasive composites
comprise second abrasive particles dispersed in a second polymeric
binder, wherein the second abrasive particles have a second average
particle size that is smaller than the first average particle size;
and c) wet abrading said at least a portion of the exposed surface
of the floor with second structured abrasive members affixed to a
second machine driver pad, the second structured abrasive members
comprising second shaped abrasive composites affixed to a second
compliant backing, wherein the second shaped abrasive composites
comprise third abrasive particles dispersed in a third polymeric
binder, wherein the third abrasive particles have a third average
particle size, and wherein the third average particle size is less
than the second average particle size; and wherein average surface
roughness R.sub.a of the abraded exposed surface of the floor
decreases during each of steps b) and c).
17. The method of claim 16, wherein the nonwoven abrasive member
comprises a floor finish stripping pad.
18. The method of claim 17, wherein average surface roughness
R.sub.z of said at least a portion of the exposed surface of the
floor decreases during each of steps a) and b).
19. The method of claim 16, wherein each of the first structured
abrasive members further comprise a compliant foam layer secured to
the first compliant backing, and an attachment interface system
having a plurality of hooks opposite the compliant foam layer.
20. The method of claim 16, wherein each of the second structured
abrasive members further comprise a compliant foam layer secured to
the second compliant backing, and an attachment interface system
having a plurality of hooks opposite the compliant foam layer.
21. The method of claim 16, wherein each of the first structured
abrasive members further comprise a first attachment interface
system secured to the first compliant backing, the first attachment
interface system having a plurality of loops opposite the first
compliant backing, wherein the first structured abrasive members
are affixed to the first machine driver pad by a first attachment
interface member having two opposed major faces having hooks
extending therefrom.
22. The method of claim 16, wherein each of the second structured
abrasive members further comprises a second attachment interface
system secured to the second compliant backing, the second
attachment interface system having a plurality of loops opposite
the second compliant backing, wherein the second structured
abrasive members are affixed to the second machine driver pad by an
attachment interface member having two opposed major faces having
hooks extending therefrom.
23. The method of claim 16, wherein the first and second machine
driver pads are compressible and resilient.
24. The method of claim 16, wherein the first shaped abrasive
composites, the second shaped abrasive composites, or both, are
precisely-shaped.
25. The method of claim 16, wherein the second average particle
size is in a range of from 400 microns to 600 microns.
26. The method of claim 16, wherein the third average particle size
is in a range of from 25 microns to 75 microns.
27. The method of claim 16, wherein at least one of the first or
second shaped abrasive composites comprises superabrasive particles
retained in a vitreous binder.
28. The method of claim 16, wherein after step c) the average
surface roughness R.sub.a of the abraded exposed surface of the
floor is less than or equal to 2.4 microns.
29. The method of claim 16, further comprising, after step c): d)
wet abrading said at least a portion of the exposed surface of the
floor with third structured abrasive members affixed to a third
compressible resilient machine driver pad, the third structured
abrasive members comprising third shaped abrasive composites
affixed to a third compliant backing, wherein the third shaped
abrasive composites comprise fourth abrasive particles dispersed in
a fourth polymeric binder, wherein the fourth abrasive particles
have a fourth average particle size, and wherein the fourth average
particle size is less than the third average particle size; and
wherein the average surface roughness R.sub.a of said at least a
portion of the exposed surface of the floor decreases during step
d).
30. The method of claim 16, wherein after step d), the average
surface roughness R.sub.a of said at least a portion of the exposed
surface of the floor is less than or equal to 80 microinches.
31. The method of claim 16, further comprising, subsequent to step
c), applying a clear polymeric finish to said at least a portion of
the exposed surface of the floor.
Description
FIELD
[0001] The present disclosure broadly relates to methods for vinyl
composition tile maintenance and repair.
BACKGROUND
[0002] Vinyl composition tile is widely used as flooring in
commercial and institutional settings such as, for example, grocery
and other retail stores, schools, hospitals, light industrial
applications (e.g., laboratories), and restaurants.
[0003] There are two types of vinyl tile. The first, vinyl asbestos
tile is comparable to asphalt tile, except that vinyl type resins
are the binder instead of asphalt or other resins. As with asphalt
tile flooring, asbestos, pigments and inert fillers are used.
[0004] Since about 1982, there have been no vinyl asbestos tiles
manufactured. The asbestos was removed and replaced with other
fillers. This type of floor tile is generally referred to as Vinyl
Composition tile (VC tile). It is more porous than vinyl asbestos
tile, and therefore more difficult to build initial gloss. Because
of the relatively high filler content, these floors are only
available in tile form. The recommended maintenance of VC tile
floors generally involves aqueous polymer emulsion coatings and
aqueous cleaners and strippers.
[0005] VC tile is generally composed of binder, fillers and
pigments compounded with additives such as, for example,
stabilizers and processing aides. The binder consists of polymers
and/or copolymers of vinyl chloride, other modifying resins, and
plasticizers. Vinyl resins are tough, chemically inert,
thermoplastic, and resistant to many solvents. Vinyl composition
tiles are formed into solid sheets of varying thicknesses (1/8-inch
(0.32-cm) is most common) by applying heat and pressure to colored
vinyl chips, and are typically cut into squares (e.g., 12-inch
(30-cm) squares). VC tile may be supplied with a surface finish
layer, but is otherwise generally substantially uniform in
appearance throughout its thickness.
[0006] Maintenance of installed VC tile flooring typically involves
coating with several coats of a clear polymeric floor finish to
achieve satisfactory gloss, followed by frequent (e.g., daily)
dusting and burnishing, less frequent scrubbing, and occasional
stripping and recoating with floor finish to maintain its
appearance.
SUMMARY
[0007] Despite regular maintenance, over the course of time VC tile
flooring (e.g., VC tile having one or more layers of floor finish
thereon) generally loses is appearance due to physical damage such
as gouging and chemical damage that may occur due to floor
stripping compositions. Further, stains due to spills (e.g., of
iodine antiseptic) may also contribute to deterioration of the
appearance of VC tile. In such cases, replacement of the floor tile
is the typical remedy; however, this process is time consuming and
expensive.
[0008] Advantageously, methods according to the present disclosure
can postpone the need for replacement of VC tile (e.g., for years),
thereby saving time, cost, and reducing environmental waste.
[0009] Further, in some embodiments, methods according to the
present disclosure can be used instead of strip and recoat
operations, whereby they can significantly reduce the mess and time
required to refurbish the floor appearance.
[0010] In one aspect, the present disclosure provides a method of
refurbishing vinyl composition tile flooring, the method comprising
sequential steps:
[0011] a) wet abrading at least a portion of an exposed surface of
a floor comprising vinyl composition tiles with first structured
abrasive members affixed to a first machine driver pad, the first
structured abrasive members comprising first shaped abrasive
composites affixed to a first compliant backing, wherein the first
shaped abrasive composites comprise first abrasive particles
dispersed in a first polymeric binder, wherein the first abrasive
particles have a first average particle size; and
[0012] b) wet abrading said at least a portion of the exposed
surface of the floor with second structured abrasive members
affixed to a second machine driver pad, the second structured
abrasive members comprising second shaped abrasive composites
affixed to a second compliant backing, wherein the second shaped
abrasive composites comprise second abrasive particles dispersed in
a second polymeric binder, wherein the second abrasive particles
have a second average particle size, and wherein the second average
particle size is less than the first average particle size; and
[0013] wherein average surface roughness R.sub.a of said at least a
portion of the exposed surface of the floor decreases during each
of steps a) and b).
[0014] In some embodiments, the method further comprises, after
step b):
[0015] c) wet abrading said at least a portion of the exposed
surface of the floor with third structured abrasive members affixed
to a third compressible resilient machine driver pad, the third
structured abrasive members comprising third shaped abrasive
composites affixed to a third compliant backing, wherein the third
shaped abrasive composites comprise third abrasive particles
dispersed in a third polymeric binder, wherein the third abrasive
particles have a third average particle size, and wherein the third
average particle size is less than the second average particle
size; and
[0016] wherein the average surface roughness R.sub.a of said at
least a portion of exposed surface of the floor decreases during
step c).
[0017] In some embodiments, the method further comprises,
subsequent to step b) or step c) (if included), applying a clear
polymeric finish to said at least a portion of the exposed surface
of the floor.
[0018] In another aspect, the present disclosure provides a method
of refurbishing vinyl flooring, the method comprising sequential
steps:
[0019] a) wet abrading at least a portion of an exposed surface of
floor comprising vinyl composition tiles with a nonwoven abrasive
member, wherein the nonwoven abrasive member comprises a nonwoven
fiber web having first abrasive particles adhered thereto by a
first polymeric binder, wherein the first abrasive particles have a
first average particle size;
[0020] b) wet abrading said at least a portion of the exposed
surface of the floor with first structured abrasive members affixed
to a first machine driver pad, the first structured abrasive
members comprising first shaped abrasive composites affixed to a
first compliant backing, wherein the first shaped abrasive
composites comprise second abrasive particles dispersed in a second
polymeric binder, wherein the second abrasive particles have a
second average particle size that is smaller than the first average
particle size; and
[0021] c) wet abrading said at least a portion of the exposed
surface of the floor with second structured abrasive members
affixed to a second machine driver pad, the second structured
abrasive members comprising second shaped abrasive composites
affixed to a second compliant backing, wherein the second shaped
abrasive composites comprise third abrasive particles dispersed in
a third polymeric binder, wherein the third abrasive particles have
a third average particle size, and wherein the third average
particle size is less than the second average particle size;
and
[0022] wherein average surface roughness R.sub.a of the abraded
exposed surface of the floor decreases during each of steps b) and
c).
[0023] In some embodiments, the method further comprises, after
step c):
[0024] d) wet abrading said at least a portion of the exposed
surface of the floor with third structured abrasive members affixed
to a third compressible resilient machine driver pad, the third
structured abrasive members comprising third shaped abrasive
composites affixed to a third compliant backing, wherein the third
shaped abrasive composites comprise fourth abrasive particles
dispersed in a fourth polymeric, binder, wherein the fourth
abrasive particles have a fourth average particle size; and wherein
the fourth average particle size is less than the third average
particle size; and
[0025] wherein the average surface roughness R.sub.a of said at
least a portion of the exposed surface of the floor decreases
during step d).
[0026] In some embodiments, the method further comprises,
subsequent to step c) or step d) (if included), applying a clear
polymeric finish to the abraded exposed surface of the floor.
[0027] Conventional nonwoven diamond abrasive floor pads conform to
height irregularities in the floor and are not very effective for
planarizing the floor surface. In contrast; the structured abrasive
members used in methods according to the present disclosure have
sufficient stiffness that they are capable of effectively abrading
off high spots on the floor and generating like new, or even better
than new, appearance.
[0028] As used herein,
[0029] the term "compliant" means yielding and/or conforming in
response to applied pressure;
[0030] the term "(meth)acryl" refers to acryl and/or methacryl;
[0031] the terms "polymer" and "polymeric" refer to an organic
polymer;
[0032] the term "subsequent" means at a later time, which may be
immediate or at a later time (e.g., after one or more intervening
abrading steps or other processes or events); and
[0033] the term "wet abrading" refers to abrading in the presence
of water, the water optionally containing one or more additional
components such as, for example, organic solvents, pH modifiers,
colorants, dyes, fragrances, disinfectants, and surfactants.
[0034] As used herein, surface roughness R.sub.a and R.sub.z are as
defined in the Examples section hereinbelow.
[0035] The features and advantages of the present disclosure will
be further understood upon consideration of the detailed
description as well as the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
[0036] FIG. 1A is a schematic side view of an exemplary structured
abrasive member 100 useful in practice of the present
disclosure.
[0037] FIG. 1B is an enlarged view of region 1B in FIG. 1A.
[0038] FIG. 1C is a schematic side view of an exemplary structured
abrasive member 105 useful in practice of the present
disclosure.
[0039] FIG. 2 is a schematic perspective bottom view of an
exemplary arrangement of structured abrasive members affixed to a
compressible resilient machine driver pad useful in practice of
methods according to the present disclosure.
[0040] While the above-identified drawing figures set forth several
embodiments of the present disclosure, other embodiments are also
contemplated, for example, as noted in the discussion. In all
cases, the disclosure is presented by way of representation and not
limitation. It should be understood that numerous other
modifications and embodiments can be devised by those skilled in
the art, which fall within the scope and spirit of the principles
of the disclosure. The figures may not be drawn to scale. Like
reference numbers may have been used throughout the figures to
denote like parts.
DETAILED DESCRIPTION
[0041] Methods according to the present disclosure are suitable for
refurbishing vinyl composition tile flooring. Preferably, prior to
practicing methods according to the present disclosure, the
flooring to be refurbished should be inspected and cracked, raised
and/or blistered, or broken tiles replaced. In some embodiments,
preexisting floor finish may be removed using conventional wet
stripping techniques. In some embodiments, preexisting floor finish
is removed using an aggressive nonwoven abrasive member; for
example, a floor finish stripping pad used in conventional wet
stripping processes. Preferably, the area of the floor involved is
cordoned off from public access during the refurbishing
process.
[0042] In one embodiment, a method of refurbishing vinyl flooring
according to the present disclosure comprises wet abrading an
exposed surface of a floor comprising vinyl composition tiles with
first structured abrasive members affixed to a first compressible
resilient machine driver pad, and then wet abrading the exposed
surface of the floor with second structured abrasive members
affixed to a second compressible resilient machine driver pad. In
some embodiments, the method then further comprises wet abrading
the exposed surface of the floor with third structured abrasive
members affixed to a third compressible resilient machine driver
pad.
[0043] After wet abrading with one of the structured abrasive
members, the abraded portion of a typical VC tile floor is smoother
(has less roughness) than before the abrading step. Of course, the
degree of roughness will depend on the initial roughness before
abrading, the duration and applied force while abrading, the nature
of the abrasive member, and the abrasive particle size. For
example, in some embodiments, after wet abrading with structured
abrasive members (e.g., steps a), b), and c); or steps b), c), and
d); depending on the embodiment) the average surface roughness
R.sub.a may be less than or equal to 120 microinches (3.05 microns)
(e.g., after wet abrading with a 300-.mu.m diamond structured
abrasive disc), 95 microinches (2.41 microns) (e.g., after wet
abrading with a 45-.mu.m diamond structured abrasive disc), 80
microinches (2.03 microns) (e.g., after wet abrading with a 0-.mu.m
diamond structured abrasive disc) down to 70 microinches (1.78
microns), 60 microinches (1.52 microns), 50 microinches (1.27
microns), 40 microinches (1.02 microns), 30 microinches (0.76
microns) (e.g., after wet abrading with a 6-.mu.m diamond
structured abrasive disc), or 20 microinches (0.51 microns), or
even less than 10 microinches (0.25 microns) (e.g., after wet
abrading with a 3-.mu.m diamond structured abrasive disc).
[0044] Similarly, the surface roughness R.sub.z of the abraded
portion of the VC the floor, after wet abrading with structured
abrasive members (e.g., steps a), b), and c); or steps b), c), and
d); depending on the embodiment) may be less than or equal to 700
microinches (17.8 microns) (e.g., after wet abrading with a
300-.mu.m diamond structured abrasive disc), 600 microinches (15.2
microns) (e.g., after wet abrading with a 45-.mu.m diamond
structured abrasive disc), 525 microinches (13.3 microns) (e.g.,
after wet abrading with a 10-.mu.m diamond structured abrasive
disc) down to 500 microinches (12.7 microns), 430 microinches (10.9
microns), 360 microinches (9.14 microns). 280 microinches (7.11
microns), 180 microinches (4.57 microns) (e.g., after wet abrading
with a 6-.mu.m diamond structured abrasive disc), or 150
microinches (3.81 microns), or even less than 100 microinches (2.54
microns) (e.g., after wet abrading with a 3-.mu.m diamond
structured abrasive disc).
[0045] Referring now to FIG. 1A, exemplary structured abrasive
member 100 comprises structured abrasive layer 110 disposed on
first surface 122 of compliant backing 120. Optional attachment
interface system 130 is secured to second surface 124 of compliant
backing 120 by adhesive layer 135. Optional attachment interface
system 130 further includes looped portion 160 of a hook and loop
fastener, and hooked interface pad 150 having hooked portions of a
hook and loop fastening system on opposing sides thereof.
[0046] Structured abrasive layer 110 comprises a plurality of
shaped abrasive composites 140, which are composites of abrasive
particles 145 distributed in a binder 148 (e.g., see FIG. 1B).
Generally, the shaped abrasive composites are rigid. Shaped
abrasive composites 140 are separated by a boundary or boundaries
associated with the shape of the shaped abrasive composite,
resulting in one shaped abrasive composite being separated to some
degree from adjacent abrasive composites. One of the earliest
references to abrasive articles with shaped abrasive composites
(e.g., precisely-shaped abrasive composites) is U.S. Pat. No.
5,162,917 (Pieper et al.). Many others have followed. The term
"precisely-shaped abrasive composite", as used herein, refers to
abrasive composites having a shape that has been formed by curing a
curable flowable mixture of abrasive particles and curable binder
precursor while the mixture is both being borne on a backing and
filling a cavity on the surface of a production tool. Such a
precisely-shaped abrasive composites have precisely the same shape
as that of the cavity. A plurality of such composites provide
three-dimensional shapes that project outward from the surface of
the backing in a non-random pattern, namely the inverse of the
pattern of the production tool. Each composite is defined by a
boundary, the base portion of the boundary being the interface with
the backing to which the precisely shaped composite is adhered. The
remaining portion of the boundary is defined by the cavity on the
surface of the production tool in which the composite was cured.
The entire outer surface of the composite is confined, either by
the backing or by the cavity, during its formation.
[0047] Useful compliant backings 120 may include those known useful
in abrasive articles such as, for example, metal, thick polymeric
sheets and/or films (e.g., polycarbonate), saturant-treated cloths
(e.g., glass and/or polyester cloth) and nonwoven fabrics, treated
or primed versions thereof, and combinations thereof. Examples
include polyester sheets, polyolefin sheets (e.g., polyethylene and
propylene sheet), polyamide sheets, polyimide sheets, and
polycarbonate sheets.
[0048] Abrasive particles 145 may comprise, for example, fused
aluminum oxide (including white fused alumina, heat-treated
aluminum oxide, and brown aluminum oxide), ceramic aluminum oxide
(including shaped ceramic alumina particles), heated treated
aluminum oxide, silicon carbide, diamond (natural and synthetic),
cubic boron nitride, boron carbide, titanium carbide, cubic boron
nitride, garnet, fused alumina-zirconia, diamond, zirconia, and
combinations thereof. Of these, diamonds are preferred. Useful
diamonds may be either natural diamonds or man-made diamonds. The
diamonds may include a surface coating (e.g., nickel or other
metal) to improve the retention of the diamonds in the resin
matrix.
[0049] Abrasive particles 145 may also be present in abrasive
aggregates. Such aggregates comprise a plurality of the abrasive
particles, a matrix material, and optional additives. The matrix
material may be organic and/or inorganic. The matrix material can
be, for example, polymer resin, glass (e.g., vitreous-bond diamond
aggregates), metal, glass-ceramic, ceramic (e.g., ceramic-bond
agglomerates as described in U.S. Pat. No. 6,790,126 (Wood et
al.)), or a combination thereof. For example, glass, such as silica
glass, glass-ceramics, borosilicate glass, phenolic, epoxy,
acrylic, and the other resins described in the context of the
composite binder can be used as the matrix material. Abrasive
aggregates may be randomly shaped or have a predetermined shape
associated with them. Additional details regarding various abrasive
aggregates and methods of making them may be found, for example, in
U.S. Pat. No. 4,311,489 (Kressner); U.S. Pat. No. 4,652,275
(Bloecher et al.); U.S. Pat. No. 4,799,939 (Bloecher et al.); U.S.
Pat. No. 5,549,962 (Holmes et al.); U.S. Pat. No. 5.975,988
(Christianson); U.S. Pat. No. 6,620,214 (McArdle), U.S. Pat. No.
6,521,004 (Culler et al.); U.S. Pat. No. 6,551,366 (D'Souza et.
al,); U.S. Pat. No. 6,645,624 (Adeftis et al.); and U.S. Pat. No.
7,169,031 (Fletcher et at); and in U.S. Publ. Patent Appl.
2007/0026770 (Fletcher et al.).
[0050] Vitreous-bond abrasive aggregates can be made, for example,
by providing a plurality of glass bodies made from the glass
binder, each glass body having a defined shape, and glass bodies
having a softening temperature, providing a plurality of abrasive
particles, mixing the plurality of glass bodies and the plurality
of abrasive particles together to form a mixture, heating the
mixture to the softening temperature of glass bodies so that glass
bodies soften while substantially retaining the defined shape,
adhering abrasive particles to the softened glass bodies to form a
plurality of abrasive aggregates, and cooling abrasive aggregates
so that the glass binder of glass bodies hardens. Further details
are described in U.S. Pat. No. 7,887,608 (Schwabel et al.).
[0051] The abrasive particles may further comprise a surface
treatment or coating such as, for example, a coupling agent or
metal or ceramic coating. Preferably, the abrasive particles have a
Mohs hardness of at least 7, preferably at least 8, and more
preferably at least 9.
[0052] The abrasive particles preferably have an average particle
size in a range of from about. 0.01 micrometer (small particles) to
500 micrometers (large particles), more preferably about 0.25
micrometers to about 500 micrometers, even more preferably about 3
micrometers to about 400 micrometers, and most preferably about 5
micrometers to about 50 micrometers. Occasionally, abrasive
particle sizes are reported as "mesh" or "grade", both of which are
commonly known abrasive particle sizing methods.
[0053] The choice of abrasive particle size will typically depend
on the point in the refurbishing process of the present disclosure
at which it is to be used, with the average size of the abrasive
particles decreasing with each successive structured abrasive
member (e.g., first, then second, and optionally then third).
[0054] Shaped abrasive composites 140 may optionally include
diluent particles, which are not sufficiently hard to serve
effectively as abrasive particles. The particle size of these
diluent particles may be on the same order of magnitude as the
abrasive particles. Examples of such diluent particles include
gypsum, marble, limestone, flint, silica, glass bubbles, glass
beads, and aluminum silicate.
[0055] Abrasive particles 145 are adhered one to another with
binder 148 to form shaped abrasive composites 140 (e.g., see FIG.
1B). Binder 148 is an organic and/or polymeric binder, and is
derived from a binder precursor. In preferred embodiments, abrasive
particles 145 are present in vitreous-bond abrasive aggregates (not
shown).
[0056] During the manufacture of structured abrasive layer 110, the
binder precursor is exposed to an energy source which aids in the
initiation of polymerization or curing of the binder precursor.
[0057] Examples of energy sources include thermal energy and
radiation energy, the latter including electron beam, ultraviolet
light, and visible light. During this polymerization process, the
binder precursor is polymerized or cured and is converted into a
solidified binder. Upon solidification of the binder precursor, the
adhesive matrix is formed.
[0058] Binder 148 can be formed, for example, of a curable (via
energy such as UV light or heat) organic binder precursor material.
Examples include alkylated urea-formaldehyde resins,
melamine-formaldehyde resins, and alkylated
benzoguanamine-formaldehyde resin, acrylate resins (including
acrylates and methacrylates) such as vinyl acrylates, acrylated
epoxies, acrylated urethanes, acrylated polyesters, acrylated
acrylics, acrylated polyethers, vinyl ethers, acrylated oils, and
acrylated silicones, alkyd resins such as urethane alkyd resins,
polyester resins, reactive urethane resins, phenolic resins such as
resole and novolac resins. phenolic latex resins, epoxy resins such
as bisphenol epoxy resins, isocyanates, isocyanurates, polysiloxane
resins (including alkylalkoxysilane resins), reactive vinyl resins,
phenolic resins (resole and novolac), and the like. The resins may
be provided as monomers, oligomers, polymers, or combinations
thereof. To facilitate curing, the binder precursor may include one
or more of photoinitiators, crosslinkers, thermal initiators,
catalysts, and combinations thereof Such materials are well known
in the art.
[0059] Another useful method of making structured abrasive members
having shaped abrasive composites where the composites comprise
abrasive aggregates fixed in a make coat, with optional size
coatings, is described in U.S. Pat. No. 6,217,413 (Christianson).
Embossing and/or screen printing may also be used to form shaped
abrasive composites as described in, for example, U.S. Pat. No,
5,014,468 (Ravipati et al.).
[0060] The structured abrasive members may have any shape such as,
for example, discs, squares, daisies, rectangular strips, rings,
crescents, spirals, wavy lines, or any 2-dimensional geometric
shape.
[0061] Examples of commercially available structured abrasive
members suitable for use in the present disclosure include, for
example, those available as 3M TRIZACT DIAMOND HX Gold, Red, and
Blue discs from 3M Company, St. Paul, Minn.
[0062] Further details concerning methods and materials for making
structured abrasive members can be found, for example, in U.S. Pat.
No. 5,152,917 (Pieper et al.) and U.S. Pat. No. 5,435,816 (Spurgeon
et al.), U.S. Pat. No. 5,437,754 (Calhoun), U.S. Pat. No. 5,454,844
(Hibbard et al.), U.S. Pat. No. 5,304,223 (Pieper et al.), and U.S.
Pat. No. 7,300,479 (McArdle et al.).
[0063] Optional attachment interface system 130 may comprise, for
example, the hooked portion of a hook and loop fastening system, or
capped stems of a self-mating mechanical fastener (e.g., as
described in U.S. Pat. No. 5,672,186 (Chesley et al.) or U.S. Pat.
No. 5,201,101 (Rouser et al.)). Optional attachment interface
system may comprise multiple elements such as, for example, a
looped portion of a hook and loop fastener in combination with an
interface pad having hooked portions of a hook and loop fastener on
opposite sides thereof, thereby providing a hooked outer surface
for mounting to the machine driver pad.
[0064] In another embodiment, shown in FIG. 1C, exemplary
structured abrasive member 105 comprises structured abrasive layer
110 disposed on first surface 122 of compliant backing 120.
Attachment interface system 137 is secured to second surface 124 of
compliant backing 120 by adhesive layer 135. As shown, attachment
interface system 137 comprises one half of a capped-stem
self-mating fastener comprising foam layer 170, auxiliary adhesive
layer 175, and capped stem backing 180. However, other attachment
interface systems having hook-type projections may also be used
(e.g., i-hook fasteners and T-hook fasteners).
[0065] Suitable optional interface layers are typically
compressible and conformable. Preferably the optional attachment
layer has sufficient overall thickness that it raises the
structured abrasive members beyond the surface of machine driver
pad to which it is attached, so that the machine driver pad does
not substantially reduce the contact pressure between the
structured abrasive members and the floor surface. Accordingly, in
some embodiments, the optional interface layer may have a thickness
in a range of from 2 millimeters to 13 millimeters, preferably from
2 millimeters to 5 millimeters.
[0066] if the optional attachment interface system is not present,
then sonic other method for mounting the pads (e.g., such as
adhesive) may be used. In such cases, and indeed in most instances,
it may be desirable multiple to securely mount structured abrasive
members to the compressible resilient nonwoven machine driver pad
to form an assembly for each type of structured abrasive member
used. Accordingly, to change from one structured abrasive member
type to another it is only necessary to change structured abrasive
member/compressible resilient machine driver pad assemblies,
instead of remounting individual structured abrasive members.
[0067] The first, second, and optional third structured abrasive
members independently comprise shaped abrasive composites affixed
to a compliant backing (i.e., the backing is prone to irreversible
mechanical damage if subjected to more than incidental flexing).
Each of the shaped abrasive composites comprises abrasive particles
dispersed in a first polymeric binder. The average particle size of
abrasive particles in each successive structured abrasive member is
smaller than the previous one, thereby resulting in ever increasing
levels of smoothness, while achieving reasonable overall abrading
rates.
[0068] While the shaped abrasive composites of the structured
abrasive members contained ever decreasing particle sizes, the
other components such as for example, binder abrasive particle
composition, compliant backing, and size, shape, and/or arrangement
of the abrasive composites may change. In some circumstances, this
may lead to increase in surface roughness of the VC tile floor, and
such combination of structured abrasive members should generally be
avoided, or followed by additional abrading steps to smooth the
floor surface. To avoid this problem, it is desirable that the
structured abrasive members be substantially the same (e.g., in
terms of the shape, size, composition, and arrangement of the
shaped abrasive composites, composition of abrasive particles, and
for the compliant backing), except for the average size of the
abrasive particles.
[0069] The machine driver pads may be made of any material capable
of supporting the structured abrasive members (e.g., metal plates,
nonwoven pads, foams, rubber discs). In some embodiments, machine
driver pads are capable of compressing and recovering without
substantial permanent deformation (i.e., they are compressible and
resilient). Compressibility and resiliency allow the machine driver
pad to float over gradual irregularities in height of the floor
(which may be cause, for example, by an underlying concrete
surface), whereas a rigid machine driver pad may be prone to
gouging the floor in such circumstances (e.g., depending on the
floor maintenance machine design). Preferably, the machine driver
pads comprise nonwoven material having a disc-shape (although other
shapes may also be used) and having a thickness and compressibility
typically of a conventional buffing pad for a swing arm buffing
machine. For example, the machine driver pads may comprise a
nonwoven fiber disc having a thickness in a range of from 1 to 5
centimeters (cm) and a diameter in a range of from 0.3 to 1 meter.
Useful nonwoven materials may comprise, for example, synthetic
fibers (e.g., polyester, polyamide, polyolefin, and bicomponent
core-shell synthetic fibers), natural fibers (e.g., banana, flax,
cotton, jute, agave, sisal, coconut, soybean, and hemp), and
combinations of the foregoing. The machine driver pad may have
abrasive particles bonded to nonwoven fibers.
[0070] Lofty nonwoven machine driver pads may be prepared according
to conventional methods such as, for example, by forming a low
density air-laid fiber web using a Rando Webber web-forming machine
commercially available from Rando Machine Corporation, Macedon,
N.Y. In some embodiments a blend of fibers may be used. One
exemplary such blend includes polyester (polyethylene
terephthalate) staple fibers and crimped sheath-core melt-bondable
polyester staple fibers. The fiber web is then optionally heated in
a hot convection oven to activate any melt-bondable fibers in the
fiber web and pre-bond the web.
[0071] Examples of suitable melt-bondable fibers are described in
U.S. Pat. No. 5,082,720 (Hayes). The fibers are preferably
tensilized and crimped, but may also be continuous filaments such
as those formed by an extrusion process, e.g., as described in U.S.
Pat. No. 4,227,350 (Fitzer).
[0072] The optionally pre-bonded fiber web is then coated with a
liquid binder precursor composition by passing it between the
coating rolls of a two roll coater, wherein the bottom coating roll
is partially immersed in the liquid binder resin composition.
Exemplary liquid binder precursor compositions include aminoplasts,
urea-formaldehyde resins, phenolics, epoxies, and urethanes,
although other binder precursors may also be used. The coated
nonwoven web is then placed in an oven heated to cure the liquid
binder precursor resin, and produce a bonded nonwoven web.
[0073] In some embodiments, the machine driver pad comprises an
open nonwoven fiber substrate (e.g., a nonwoven fiber disc) that
has no external backing layer. Suitable nonwoven compressible
resilient backings are also available from commercial sources such
as, for example, 3M WHITE SUPER POLISH PAD 4100 , 3M RED BUFFER PAD
5100, and 3M NATURAL BLEND WHITE PAD 3300 floor pads all from 3M
Company, St. Paul., Minn. In some embodiments, the compressible
resilient backing may comprise a foam. (e.g., a foam disc).
Laminate constructions such as, for example, foam and nonwoven
fiber web laminate may also be used.
[0074] VC tile is generally substantially uniform in appearance
throughout its thickness. VC tile is widely available from
commercial suppliers such as, for example, Armstrong World
Industries, Inc., Lancaster, Pa.; Mannington Mills, Salem, N.J.;
and Congoleum Corp., Mercerville, N.J.
[0075] The structured abrasive members are secured to the
compressible resilient backing the first structured abrasive
members, the second structured abrasive members, or optionally the
third structured abrasive members), which in turn is typically
mounted to a low speed (i.e., from about 175 to about 350
revolutions per minute) mechanical device of the type used to
maintain VC tile flooring. Examples include manually operated
rotary floor machines and walk-behind or riding autoscrubbers. FIG.
2 shows an exemplary assembly 200 of structured abrasive members
100 affixed to a machine driver pad 210 that is useful in practice
of the present disclosure. Any appropriate number of structured
abrasive members may be used (e.g., the number of structured
abrasive members may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more), in
any arrangement. Typically, the structured abrasive members are
symmetrically arranged on the surface of the compressible resilient
machine driver pad, although other arrangements may also be used.
Also, the structured abrasive members are typically positioned so
that they are adjacent the peripheral edge of the compressible
resilient machine driver pad, although other arrangements may also
be used.
[0076] In some embodiments, a non-woven pad having diamonds bonded
thereto may be useful for final burnishing of the VC tile flooring
after the wet abrading steps (e.g., a), b), and optionally c)) with
structured abrasive members. Examples include those available as 3M
SCOTCH-BRITE PURPLE DIAMOND FLOOR PAD PLUS and 3M SCOTCH-BRITE
SIENNA DIAMOND FLOOR PAD PLUS from 3M Company. Such pads may also
be used in one or more additional slow speed wet abrading steps
that can optionally be used to augment processes according to the
present disclosure. High-speed burnishing (e.g., at speeds in
excess of 1000 revolutions per minute) to improve the aesthetic
quality of the surface of the floor is preferably used as a final
step in processes according to the present disclosure, however this
is not a requirement. High speed burnishing can be carried out
using methods well known in the art, for example, using a electric,
battery, or propane burnishing machine.
[0077] VC tile flooring may be pre-conditioned so that it is more
suited to abrading according to the present disclosure. For
example, existing floor finish may be removed using a chemical
stripper and a nonwoven stripping pad. Desirably, chemical
stripping is omitted as it is messy, time consuming, and
aesthetically unpleasant. Accordingly, in some embodiments, no
pre-conditioning step is used, while in others, an aggressive
abrasive floor pad is used to remove the finish without aid of
stripper (although water may be useful for dust control). Examples
of such aggressive abrasive floor pads are available as 3M BLACK
STRIPPER PAD 7200, 3M BROWN STRIPPER PAD 7100, 3M HIGH PRODUCTIVITY
PAD 7300, and 3M CLEAN AND STRIP XT floor pads, all from 3M
Company.
[0078] Whether the floor is pre-conditioned or not, a portion of
the exposed surface of VC tile floor is abraded with first
structured abrasive members affixed to the first compressible
resilient machine driver pad, the first structured abrasive members
comprising first shaped abrasive composites affixed to a first
compliant backing, wherein the first shaped abrasive composites
comprise first abrasive particles dispersed in a first polymeric
binder, wherein the first abrasive particles have a first average
particle size. In some embodiments, the first average particle size
is in a range of from 200 to 400 microns, preferably from 250 to
350 microns.
[0079] After the first wet abrading step is complete, the process
is repeated again using the second structured abrasive members with
second abrasive particles having a second average particle size
that is smaller than the first average particle size. In some
embodiments, the second average particle size is in a range of from
25 to 75 microns, preferably from 35 to 65 microns.
[0080] After the wet abrading steps using the first and second
structured abrasive members are complete, the floor may be
sufficiently restored for use. However, in some instances it may be
desirable to carry out additional (for example, a third and
optionally a fourth) wet abrading processes as above, but using
successively smaller average abrasive particle sizes.
[0081] Once the VC tile floor has been abraded (i.e., resurfaced
and/or restored) as described above, a clear polymeric finish may
be applied to enhance appearance and protect the floor from wear.
The clear polymeric finish may include water-soluble or
water-dispersible film formers such as metal-free acrylic finishes,
acid-containing polymers crosslinked using transition metals, and
water-soluble or water-dispersible multicomponent (e.g.,
two-component) polyurethanes. The clear polymeric finish may
contain mixtures of film formers.
[0082] Examples of suitable commercially available clear polymeric
finishes include acrylic floor finishes 3M SCOTCHGARD VINYL FLOOR
PROTECTOR, 3M CORNERSTONE, 3M SCOTCHGARD UHS 25 FLOOR FINISH, and
3M SCOTCHGARD LM 25 FLOOR. FINISH, and polyurethane finishes such
as 3M SCOTCHGARD ULTRA DURABLE FLOOR FINISH from 3M Company, Saint
Paul, Minn.
SELECTED EMBODIMENTS OF THE PRESENT DISCLOSURE
[0083] In a first embodiment, the present disclosure provides a
method of refurbishing vinyl composition tile flooring, the method
comprising sequential steps:
[0084] a) wet abrading at least a portion of an exposed surface of
a floor comprising vinyl composition tiles with first structured
abrasive members affixed to a first machine driver pad, the first
structured abrasive members comprising first shaped abrasive
composites affixed to a first compliant backing, wherein the first
shaped abrasive composites comprise first abrasive particles
dispersed in a first polymeric binder, wherein the first abrasive
particles have a first average particle size; and
[0085] b) wet abrading said at least a portion of the exposed
surface of the floor with second structured abrasive members
affixed to a second machine driver pad, the second structured
abrasive members comprising second shaped abrasive composites
affixed to a second compliant backing, wherein the second shaped
abrasive composites comprise second abrasive particles dispersed in
a second polymeric binder, wherein the second abrasive particles
have a second average particle size, and wherein the second average
particle size is less than the first average particle size; and
[0086] wherein average surface roughness R.sub.a of said at least a
portion of the exposed surface of the floor decreases during each
of steps a) and b).
[0087] In a second embodiment, the present disclosure provides a
method according to the first embodiment, wherein average surface
roughness R.sub.z of said at least a portion of the exposed surface
of the floor decreases during each of steps a) and b).
[0088] In a third embodiment, the present disclosure provides a
method according to the first or second embodiment, wherein each of
the first structured abrasive members further comprise a first
attachment interface system secured to the first compliant backing,
the first attachment interface system having a plurality of loops
opposite the first compliant backing, wherein the first structured
abrasive members are affixed to the first machine driver pad by a
first attachment interface member having two opposed major faces
having hooks extending therefrom.
[0089] In a fourth embodiment, the present disclosure provides a
method according to any of the first to third embodiments, wherein
each of the first structured abrasive members further comprise a
first compliant foam layer secured to the first compliant backing,
and an attachment interface system having a plurality of hooks
opposite the first compliant foam layer.
[0090] In a fifth embodiment, the present disclosure provides a
method according to any of the first to fourth embodiments, wherein
each of the second structured abrasive members further comprise a
second compliant foam layer secured to the second compliant
backing, and an attachment interface system having a plurality of
hooks opposite the second compliant foam layer.
[0091] In a sixth embodiment, the present disclosure provides a
method according to any of the first to fifth embodiments, wherein
each of the second structured abrasive members further comprises a
second attachment interface system secured to the second compliant
backing, the second attachment interface system having a plurality
of loops opposite the second compliant backing, wherein the second
structured abrasive members are affixed to the second machine
driver pad by an attachment interface member having two opposed
major faces having hooks extending therefrom.
[0092] In a seventh embodiment, the present disclosure provides a
method according to any of the first to sixth embodiments, wherein
the first and second machine driver pads are compressible and
resilient.
[0093] In an eighth embodiment, the present disclosure provides a
method according to any of the first to seventh embodiments,
wherein the first shaped abrasive composites, the second shaped
abrasive composites, or both, are precisely-shaped.
[0094] In a ninth embodiment, the present disclosure provides a
method according to any of the first to eighth embodiments, wherein
the first average particle size is in a range of from 400 microns
to 600 microns.
[0095] In a tenth embodiment, the present disclosure provides a
method according to any of the first to ninth embodiments, wherein
the second average particle size is in a range of from 25 microns
to 75 microns.
[0096] In an eleventh embodiment, the present disclosure provides a
method according to any of the first to tenth embodiments, wherein
at least one of the first or second shaped abrasive composites
comprises superabrasive particles retained in a vitreous
binder.
[0097] In a twelfth embodiment, the present disclosure provides a
method according to any of the first to eleventh embodiments,
wherein after step b) the average surface roughness R.sub.a of said
at least a portion of the exposed surface of the floor is less than
or equal to 95 microinches.
[0098] In a thirteenth embodiment, the present disclosure provides
a method according to any of the first to twelfth embodiments,
further comprising, after step b):
[0099] c) wet abrading said at least a portion of the exposed
surface of the floor with third structured abrasive members affixed
to a third compressible resilient machine driver pad, the third
structured abrasive members comprising third shaped abrasive
composites affixed to a third compliant backing, wherein the third
shaped abrasive composites comprise third abrasive particles
dispersed in a third polymeric binder, wherein the third abrasive
particles have a third average particle size, and wherein the third
average particle size is less than the second average particle
size; and
[0100] wherein the average surface roughness R.sub.a of said at
least a portion of the exposed surface of the floor decreases
during step c).
[0101] In a fourteenth embodiment, the present disclosure provides
a method according to any of the first to thirteenth embodiments,
wherein after step c), the abraded exposed surface of the floor has
an average surface roughness of less than 80 microinches.
[0102] In a fifteenth embodiment, the present disclosure provides a
method according to any of the first to fourteenth embodiments,
further comprising, subsequent to step b), applying a clear
polymeric finish to said at least a portion of the exposed surface
of the floor.
[0103] In a sixteenth embodiment, the present disclosure provides a
method of refurbishing vinyl flooring, the method comprising
sequential steps:
[0104] a) wet abrading at least a portion of an exposed surface of
a floor comprising vinyl composition tiles with a nonwoven abrasive
member. Wherein the nonwoven abrasive member comprises a nonwoven
fiber web having first abrasive particles adhered thereto by a
first polymeric binder, wherein the first abrasive particles have a
first average particle size;
[0105] b) wet abrading said at least a portion of the exposed
surface of the floor with first structured abrasive members affixed
to a first machine driver pad, the first structured abrasive
members comprising first shaped abrasive composites affixed to a
first compliant backing. Wherein the first shaped abrasive
composites comprise second abrasive particles dispersed in a second
polymeric binder, wherein the second abrasive particles have a
second average particle size that is smaller than the first average
particle size; and
[0106] c) wet abrading said at least a portion of the exposed
surface of the floor with second structured abrasive members
affixed to a second machine driver pad, the second structured
abrasive members comprising second shaped abrasive composites
affixed to a second compliant backing, wherein the second shaped
abrasive composites comprise third abrasive particles dispersed in
a third polymeric binder, wherein the third abrasive particles have
a third average particle size, and Wherein the third average
particle size is less than the second average particle size;
and
[0107] wherein average surface roughness R.sub.a of the abraded
exposed surface of the floor decreases during each of steps b) and
e).
[0108] In a seventeenth embodiment, the present disclosure provides
a method according to the sixteenth embodiment, wherein the
nonwoven abrasive member comprises a floor finish stripping
pad.
[0109] In an eighteenth embodiment, the present disclosure provides
a method according to the sixteenth or seventeenth embodiment,
wherein average surface roughness R.sub.z of said at least a
portion of the exposed surface of the floor decreases during each
of steps a) and b).
[0110] In a nineteenth embodiment, the present disclosure provides
a method according to any of the sixteenth to eighteenth
embodiments, wherein each of the first structured abrasive members
further comprise a first compliant foam layer secured to the first
compliant backing, and an attachment interface system having a
plurality of hooks opposite the first compliant foam layer.
[0111] In a twentieth embodiment, the present disclosure provides a
method according to any of the sixteenth to nineteenth embodiments,
wherein each of the second structured abrasive members further
comprise a second compliant foam layer secured to the second
compliant backing, and an attachment interface system having a
plurality of hooks opposite the second compliant foam layer.
[0112] In an twenty-first embodiment, the present disclosure
provides a method according to any of the sixteenth to twentieth
embodiments, wherein each of the first structured abrasive members
further comprise a first attachment interface system secured to the
first compliant backing, the first attachment interface system
having a plurality of loops opposite the first compliant backing,
wherein the first structured abrasive members are affixed to the
first machine driver pad by a first attachment interface member
having two opposed major faces having hooks extending
therefrom.
[0113] In a twenty-second embodiment, the present disclosure
provides a method according to any of the sixteenth to twenty-first
embodiments, wherein each of the second structured abrasive members
further comprises a second attachment interface system secured to
the second compliant backing, the second attachment interface
system having a plurality of loops opposite the second compliant
backing, wherein the second structured abrasive members are affixed
to the second machine driver pad by an attachment interface member
having two opposed major faces having hooks extending
therefrom.
[0114] In a twenty-third embodiment, the present disclosure
provides a method according to any of the sixteenth to
twenty-second embodiments, wherein the first and second machine
driver pads are compressible and resilient.
[0115] In a twenty-fourth embodiment, the present disclosure
provides a method according to any of the sixteenth to twenty-third
embodiments, wherein the first shaped abrasive composites, the
second shaped abrasive composites, or both, are
precisely-shaped.
[0116] In a twenty-fifth embodiment, the present disclosure
provides a method according to any of the sixteenth to
twenty-fourth embodiments, wherein the second average particle size
is in a range of from 400 microns to 600 microns.
[0117] In a twenty-sixth embodiment, the present disclosure
provides a method according to any of the sixteenth to twenty-fifth
embodiments, wherein the third average particle size is in a range
of from 25 microns to 75 microns.
[0118] In a twenty-seventh embodiment, the present disclosure
provides a method according to any of the sixteenth to twenty-sixth
embodiments, wherein at least one of the first or second shaped
abrasive composites comprises superabrasive particles retained in a
vitreous binder.
[0119] In a twenty-eighth embodiment, the present disclosure
provides a method according to any of the sixteenth to
twenty-seventh embodiments, wherein after step c) the average
surface roughness R.sub.a of the abraded exposed surface of the
floor is less than or equal to 2.4 microns.
[0120] In a twenty-ninth embodiment, the present disclosure
provides a method according to any of the sixteenth to
twenty-eighth embodiments, further comprising, after step c):
[0121] d) wet abrading said at least a portion of the exposed
surface of the floor with third structured abrasive members affixed
to a third compressible resilient machine driver pad, the third
structured abrasive members comprising third shaped abrasive
composites affixed to a third compliant backing, wherein the third
shaped abrasive composites comprise fourth abrasive particles
dispersed in a fourth polymeric binder, wherein the fourth abrasive
particles have a fourth average particle size, and wherein the
fourth average particle size is less than the third average
particle size; and
[0122] where the average surface roughness R.sub.a of said at least
a portion of the exposed surface of the floor decreases during step
d).
[0123] In a thirtieth embodiment, the present disclosure provides a
method according to any of the sixteenth to twenty-ninth
embodiments, wherein after step d), the average surface roughness
R.sub.a of said at least a portion of the exposed surface of the
floor is less than or equal to 80 microinches.
[0124] In a thirty-first embodiment, the present disclosure
provides a method according to any of the sixteenth to thirtieth
embodiments, further comprising, subsequent to step c), applying a
clear polymeric finish to said at least a portion of the exposed
surface of the floor.
[0125] Objects and advantages of this disclosure are further
illustrated by the following non-limiting examples, but the
particular materials and amounts thereof recited in these examples,
as well as other conditions and details, should not be construed to
unduly limit this disclosure.
EXAMPLES
[0126] Unless otherwise noted, all parts, percentages, ratios, etc.
in the Examples and the rest of the specification are by
weight.
Materials Used in the Examples
[0127] 3M SCOTCHGARD VINYL FLOOR PROTECTOR is an aqueous mixture of
a polymer and nano-sized, inorganic particles, designed for use as
a floor protector from 3M Company.
[0128] "T300" refers to a 5-inch (13-centimeter) diameter 300-.mu.m
diamond structured abrasive disc, having microreplicated composite
diamond abrasive structures on a flexible cloth backing, supplied
with a 3M hook mounting disc, and obtained under the trade
designation "3M TRIZACT DIAMOND HX GOLD" from 3M Company.
[0129] "T45" refers to a 5-inch (13-centimeter) diameter 45-.mu.m
diamond structured abrasive disc, having microreplicated composite
diamond abrasive structures on a flexible cloth backing, supplied
with a 3M hook mounting disc, and obtained under the trade
designation "3M TRIZACT DIAMOND FIX RED" from 3M Company.
[0130] "T10" refers to a 5-inch (13-centimeter) diameter 10-.mu.m
diamond structured abrasive disc, having microreplicated composite
diamond abrasive structures on a flexible cloth backing, supplied
with a 3M hook mounting disc, and obtained under the trade
designation "3M TRIZACT DIAMOND HX BLUE" from 3M Company.
[0131] "T6" refers to a 5-inch (13-centimeter) diameter 6-.mu.m
diamond structured abrasive disc, having microreplicated composite
diamond abrasive structures on a 5-mil (130-micron) film laminated
to a polycarbonate backing, obtained under the trade designation
"3M TRIZACT 673LA grade A6" from 3M Company.
[0132] "T3" refers to a 5-inch (13-centimeter) diameter 3-.mu.m
diamond structured abrasive disc, having microreplicated composite
diamond abrasive structures on a 5-mil (130-micron) film laminated
to a polycarbonate backing, "3M TRIZACT 673LA grade A3" from 3M
Company.
[0133] "PDP" refers to a 20-inch (43-centimeter) diameter diamond
abrasive nonwoven floor polishing pad, obtained under the trade
designation "3M SCOTCH-BRITE PURPLE DIAMOND FLOOR PAD PLUS" from 3M
Company.
[0134] "WSP1" refers to a 17-inch (43-centimeter) diameter nonwoven
floor polishing pad, obtained under the trade designation "3M WHITE
SUPERPOLISH PAD 4100" from 3M Company.
[0135] "WSP2" refers to a 20-inch (43-centimeter) diameter nonwoven
floor polishing pad, obtained under the trade designation "3M WHITE
SUPERPOLISH PAD 4100" from 3M Company.
Test Methods
Surface Roughness Measurement
[0136] The surface roughness of the vinyl composite (VC) tile is
defined by R.sub.z and R.sub.a. The R.sub.a of a surface is the
measurement of the arithmetic average of the scratch depth. It s
the average of 5 individual roughness depths of five successive
measuring lengths, where an individual roughness depth is the
vertical distance between the highest point and a center line.
R.sub.z is the average of 5 individual roughness depths of a
measuring length, where an individual roughness depth is the
vertical distance between the highest point and the lowest point.
Surface roughness data reported in Table 1 are the average of six
measurements taken on six VC tile specimens, using a profilometer,
available under the trade designation "SURTRONIC 25 PROFILOMETER"
from Taylor Hobson, Inc., Leicester, England.
Gloss Measurement
[0137] The gloss of the VC tile samples was measured at angles of
20, 60 and 85 degrees using a gloss meter, model "4430", obtained
from BYK-Gardner, Columbia, Md. Gloss data reported in Tables 1 and
2 are the average of six measurements taken on six VC tile
specimens.
Dry Static Coefficient of Friction (DSCF) Measurement
[0138] The Dry Static Coefficient of Friction (DSCF) of VC tile was
measured using a tribometer, model "BOT-3000", obtained from Regan
Scientific Instruments, Inc., Southlake, Tex. DSCF data reported in
Tables 1 and 2 are the average of four measurements taken on one VC
tile specimen.
[0139] In Examples 1-10 and Comparative Examples B-D, when using
diamond structured abrasive discs to abrade the floor, the process
was carried out in the presence of water as applied by a string
mop. The resultant abrasive slurry was removed from the surface of
the floor after completing wet abrading step(s) with each type of
diamond structured abrasive disc. High speed burnishing was carried
out dry.
Examples 1-2
[0140] A 6 feet by 5 feet (1.83 meters by 1.52 meters) area of worn
vinyl composition floor tile that had been subjected to frequent
pedestrian traffic aver several months was subjected to the
following abrading steps.
[0141] An interface pad having hooks on both surfaces, supplied
with the diamond structured abrasive discs (above) was attached to
a swing-type floor machine equipped with a WSP1. machine driver pad
which operates at 175 revolutions per minute. Four T300 discs were
then attached to the interface pad and the test area honed four
times with the floor machine at 88 ft/min (26.82 metersimin).
Surface finish, gloss and dry static coefficient of friction values
were then measured. The T300 discs were replaced with T45 discs and
the process repeated, after which the surface finish, gloss and dry
static coefficient of friction values were again measured. The
abrading process continued using successively finer T10 abrading
discs. Surface finish, gloss and dry static coefficient of friction
values were measured after each abrading step.
[0142] Half of the test area was marked off and designated "E-1"
for Example 1, and the other half designated "E-2" for Example 2.
The T10 abrading discs were replaced with T6 discs and the Area E-2
abraded four times with the floor machine at 88 ft/min (26.82
meters/min). The T6 discs were then replaced with T3 discs and area
E-2 was again abraded in the same manner. The entire test areas of
E-1 and E-2 were then burnished by six passes using a high speed
burnisher, model "SPEEDSHINE 2000", Obtained Tennant Trend, Inc.,
Holland, Mich., with a PDP floor abrading pad, at 88 ft/min (26.82
meters/min) (1.sup.st PDP step). A vinyl composition tile
protector, trade designation "3M SCOTCHGARD VINYL FLOOR PROTECTOR"
from 3M Company, was applied to the burnished area using a "3M EASY
SHINE APPLICATOR SYSTEM" and the burnishing step repeated (2.sup.nd
PDP step), followed by six passes with a WSP2 floor pad (1.sup.st
WSP step). The entire test area was again coated with the vinyl
floor protector, then burnished again with the PDP and the WSP
floor pads as described above (3.sup.rd PDP and 2.sup.nd WSP steps,
respectively). Surface finish, gloss and dry static coefficient of
friction values were then measured for both areas E-1 and E-2.
Results are reported in Table 1 (below).
TABLE-US-00001 TABLE 1 ABRADING STEP SURFACE FINISH R.sub.a R.sub.z
GLOSS, gloss units microinches microinches 20 60 85 (microns)
(microns) degree degree degree DSCF EXAMPLE 1 T300 98.5 (2.50) 585
(14.86) 1.0 2.3 3.5 0.68 T45 77.0 (1.96) 520 (13.21) 1.1 3.1 10.7
0.65 T10 60.7 (1.54) 454 (11.53) 1.3 5.7 31.0 0.62 1.sup.st PDP
47.4 (1.20) 403 (10.24) 14.8 42.4 60.7 0.55 2.sup.nd PDP 30.2
(0.77) 314 (7.98) 21.6 55.0 72.6 NM 1.sup.st WSP NM NM 23.9 55.6
70.2 NM 3.sup.rd PDP 19.8 (0.50) 179 (4.55) 20.9 58.4 79.5 0.70
2.sup.nd WSP NM NM 27.4 63.7 78.2 NM EXAMPLE 2 T300 98.5 (2.50) 585
(14.86) 1.0 2.3 3.5 0.68 T45 77.0 (1.96) 520 (13.21) 1.1 3.1 10.7
0.65 T10 60.7 (1.54) 454 (11.53) 1.3 5.7 31.0 0.62 T6 37.5 (0.95)
335 (8.51) 2.7 14.2 50.2 0.61 T3 35.7 (0.91) 330 (8.38) 5.2 19.7
53.7 0.58 1.sup.st PDP 33.7 (0.86) 316 (8.03) 21.2 47.7 67.0 0.59
2.sup.nd PDP 17.0 (0.43) 193 (4.90) 28.3 58.9 74.8 NM 1.sup.st WSP
NM NM 33.1 63.3 76.3 NM 3.sup.rd PDP 7.9 (0.20) 81 (2.06) 30.5 62.1
81.9 0.72 2.sup.nd WSP NM NM 41.1 70.6 82.1 NM
Example 3 and Comparative Example A
[0143] These examples were carried out using a vinyl composition
tile floor in a laboratory building. The floor area was stripped
and rinsed. A separate area of the same floor was used for each
example. Example 3 used structured abrasive discs to prepare the
floor for coating with 3M SCOTCHGARD VINYL FLOOR PROTECTOR as
described below. Comparative Example A used the floor preparation
procedure outlined in the 3M SCOTCHGARD VINYL FLOOR PROTECTOR
Technical Data sheet (dated February 2011) to prepare the floor.
After floor preparation, both examples followed the 3M SCOTCHGARD
VINYL FLOOR PROTECTOR Technical Data sheet (dated February 2011)
application procedure.
[0144] For Example 3, the floor was treated as follows: [0145] 1. 4
passes with T300 diamond structured abrasive discs [0146] 2. 4
passes with T45 diamond structured abrasive discs [0147] 3. 4
passes with T10 diamond structured abrasive discs [0148] 4. 4
passes with T6 diamond structured abrasive discs [0149] 5. 4 passes
with T3 diamond structured abrasive discs [0150] 6. 1.sup.st coat
of 3M SCOTCHGARD VINYL FLOOR PROTECTOR floor finish from 3M
Company. [0151] 7. Burnish with PDP polishing pad [0152] 8. Burnish
with WSP polishing pad [0153] 9. 2.sup.nd coat of 3M SCOTCHGARD
VINYL: FLOOR PROTECTOR floor finish [0154] 10. Burnish with PDP
polishing pad [0155] 11. Burnish with WSP polishing pad
[0156] For Comparative Example A, the floor was treated as follows:
[0157] 1. Burnish with 3M SCOTCH-BRITE SIENNA DIAMOND FLOOR PAD
PLUS polishing pad, 3M Company [0158] 2. Burnish with PDP [0159] 3.
coat of 3M SCOTCHGARD VINYL FLOOR PROTECTOR floor finish [0160] 4.
Burnish with PDP [0161] 5. Burnish with WSP [0162] 6. 2.sup.nd coat
of 3M SCOTCHGARD VINYL FLOOR PROTECTOR floor finish [0163] 7.
Burnish with PDP polishing pad [0164] 8. Burnish with WSP polishing
pad
[0165] A BYK-Gardner gloss meter (BYK-Gardner, Columbia, Md.) was
used to measure 20.degree. and 60.degree. gloss. A Perthometer M1
profilometer from Mahr Federal, Inc., Providence, R.I., was used to
measure surface roughness, R.sub.a and R.sub.z. An Elcometer 6015
NOVO-GLOSS Q DOI haze meter (Elcometer, Inc., Rochester Hills,
Mich.) was used to measure distinctness of image (DOI), haze, and
peak specular reflectance (R.sub.spec). Measurements were taken
from four different locations in each abraded testing area. The
averages of these measurements are shown in Table 2 (below).
TABLE-US-00002 TABLE 2 20.degree. 60.degree. R.sub.a, R.sub.z,
GLOSS, GLOSS, DOI value R.sub.spec, HAZE, microinches microinches
gloss units gloss units (0-100 scale) gloss units haze units
(microns) (microns) Initial Floor 1.2 4.6 0.0 0.3 1.1 72.2 520.3
Condition (1.83) (13.22) Example 3 55.8 85.3 87.0 46.3 3.9 5.9 47.8
(0.15) (1.21) Comparative 30.7 72.4 38.8 12.0 14.0 20.8 160.5
Example A (0.53) (4.07)
Examples 4-10 and Comparative Examples B-D
[0166] These examples were carried out on a vinyl composition tile
floor in a laboratory building. The floor area was stripped and
rinsed. A separate area of the same floor was used for each
example. Examples 4-10 and Comparative Examples B-C used structured
abrasive discs in different combinations to prepare the floor for
coating with 3M SCOTCHGARD VINYL FLOOR PROTECTOR floor finish,
whereas Comparative Example D only burnished the floor with a PDP
floor pad to prepare the floor. After floor preparation, all
examples followed the 3M SCOTCHGARD VINYL FLOOR PROTECTOR Technical
Data sheet (dated February 2011) application procedure.
Example 4
[0167] 1. Four passes with T45 diamond structured abrasive discs
[0168] 2. Four passes with T10 diamond structured abrasive discs
[0169] 3. Burnish with PDP polishing pad
Example 5
[0169] [0170] 1. Four passes with T300 diamond structured abrasive
discs [0171] 2. Four passes with T45 diamond structured abrasive
discs [0172] 3. Four passes with T10 diamond structured abrasive
discs [0173] 4. Burnish with PDP polishing pad
Example 6
[0173] [0174] 1. Four passes with T300 diamond structured abrasive
discs [0175] 2. Four passes with T10 diamond structured abrasive
discs [0176] 3. Burnish with PDP polishing pad
Comparative Example B
[0176] [0177] 1. Four passes with T300 diamond structured abrasive
discs [0178] 2. Burnish with PDP polishing pad
Example 7
[0178] [0179] 1. Four passes with T45 diamond structured abrasive
discs [0180] 2. Four passes with T10 diamond structured abrasive
discs [0181] 3. Burnish with PDP polishing pad
Comparative Example C
[0181] [0182] 1. Four passes with T45 diamond structured abrasive
discs [0183] 2. Burnish with PDP polishing pad
Example 8
[0183] [0184] 1. Four passes with T300 diamond structured abrasive
discs [0185] 2. Four passes with T45 diamond structured abrasive
discs [0186] 3. Four passes with T10 diamond structured abrasive
discs
Example 9
[0186] [0187] 1. Four passes with T300 diamond structured abrasive
discs [0188] 2. Four passes with T45 diamond structured abrasive
discs [0189] 3. Four passes with T10 diamond structured abrasive
discs [0190] 4. Four passes with T6 diamond structured abrasive
discs
Example 10
[0190] [0191] 1. Four passes with T300 diamond structured abrasive
discs [0192] 2. Four passes with T45 diamond structured abrasive
discs [0193] 3. Four passes with T10 diamond structured abrasive
discs [0194] 4. Four passes with T6 diamond structured abrasive
discs [0195] 5. Four passes with T3 diamond structured abrasive
discs
Comparative Example D
[0196] 1. Burnish with PDP polishing pad
[0197] Measurements were made at six different locations in each
abraded test floor area. The averages of these measurements are
shown in Table 3 (below).
TABLE-US-00003 TABLE 3 20.degree. 60.degree. R.sub.a, R.sub.z,
GLOSS, GLOSS, DOI value R.sub.spec, HAZE, microinches microinches
gloss units gloss units (0-100 scale) gloss units haze units
(microns) (microns) Initial Floor 1.1 4.6 0.0 0.3 0.8 117.3 736.1
Condition (2.98) (18.70) Example 4 32.8 57.3 59.5 14.5 8.4 33.7
258.0 (0.86) (6.55) Example 5 32.9 56.5 59.4 14.2 83 32.8 222.3
(0.83) (5.65) Example 6 25.4 51.1 51.3 10.6 9.4 33.9 214.2 (0.86)
(5.44) Comparative 15.9 42.9 34.7 5.6 12.1 63.8 382.2 Example B
(1.62) (9.71) Example 7 35.8 59.8 60.6 14.5 7.9 28.8 221.8 (0.73)
(5.63) Comparative 24.7 50.3 51.7 9.3 10.2 51.3 342.0 Example C
(1.30) (8.69) Example 8 30.2 56.1 64.0 15.1 8.1 44.7 319.2 (1.14)
(8.11) Example 9 35.1 59.7 62.1 19.6 7.0 27.6 236.7 (0.70) (6.01)
Example 10 37.1 60.2 68.6 21.2 5.8 22.3 192.7 (0.57) (4.89)
Comparative 11.2 35.6 27.3 3.3 13.9 65.9 371.2 Example D (1.67)
(9.43)
[0198] All patents and publications referred to herein are hereby
incorporated by reference in their entirety. All examples given
herein are to be considered non-limiting unless otherwise
indicated. Various modifications and alterations of this disclosure
may be made by those skilled in the art without departing from the
scope and spirit of this disclosure, and it should be understood
that this disclosure is not to be unduly limited to the
illustrative embodiments set forth herein.
* * * * *