U.S. patent application number 15/830785 was filed with the patent office on 2018-07-05 for abrasive buffing articles.
The applicant listed for this patent is SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.. Invention is credited to Ying CAI, Mike D. SHAPPELL, Jianna WANG, Shu YANG.
Application Number | 20180185986 15/830785 |
Document ID | / |
Family ID | 62708763 |
Filed Date | 2018-07-05 |
United States Patent
Application |
20180185986 |
Kind Code |
A1 |
WANG; Jianna ; et
al. |
July 5, 2018 |
ABRASIVE BUFFING ARTICLES
Abstract
The present disclosure relates to abrasive buffing articles
("abrasive buffs") and methods of making the same. The abrasive
buffs include a substrate, such as a fabric, that has been
impregnated with an abrasive polymeric composition that includes
abrasive particles, such as primary abrasive particles and/or
abrasive aggregates, such as spray dried abrasive aggregates. The
abrasive buffs are flexible and capable of conforming to and
effectively abrading, polishing, and buffing workpieces possessing
a complex geometry.
Inventors: |
WANG; Jianna; (Grafton,
MA) ; CAI; Ying; (Niskayuna, NY) ; SHAPPELL;
Mike D.; (Henderson, KY) ; YANG; Shu;
(Worcester, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIVES, INC.
SAINT-GOBAIN ABRASIFS |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Family ID: |
62708763 |
Appl. No.: |
15/830785 |
Filed: |
December 4, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62441216 |
Dec 31, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24D 13/12 20130101;
B24D 13/04 20130101; B24D 13/08 20130101 |
International
Class: |
B24D 13/08 20060101
B24D013/08 |
Claims
1. An abrasive buff comprising: a plurality of woven fabric layers;
and an abrasive composition fixed to each of the fabric layers,
wherein each of the fabric layers comprises a plurality of yarns,
wherein the abrasive composition is disposed at least partially
within the yarns, and wherein the abrasive composition comprises: a
polymeric binder and a plurality of abrasive particles dispersed in
the polymeric binder.
2. The abrasive buff of claim 1, wherein the abrasive composition
comprises: 15 wt % to 90 wt % of the abrasive buff.
3. The abrasive buff of claim 1, wherein fabric layers comprise: 10
wt % to 85 wt % of the abrasive buff.
4. The abrasive buff of claim 1, wherein the woven fabric layer
comprises a woven cloth.
5. The abrasive buff of claim 4, wherein the woven cloth comprises
a thread count in a range from 50 to 300 threads per inch in the
warp direction.
6. The abrasive buff of claim 4, wherein the woven cloth comprises
a thread count in a range from 50 to 300 threads per inch in the
weft direction.
7. The abrasive buff of claim 4, wherein woven cloth comprises a
ratio of warp thread count to weft thread count ranging from 1:1.8
to 1:1.
8. The abrasive buff of claim 4, wherein the woven cloth comprises
fibers having a linear density in a range of 0.1 denier to 500
denier.
9. The abrasive buff of claim 1, wherein the fabric comprises a
weight of grams per square meter ("GSM") in a range of 100 to 800
GSM.
10. The abrasive buff of claim 1, wherein the fabric comprises
synthetic fibers, natural fibers, or a combination thereof.
11. The abrasive buff of claim 1, wherein the woven fabric layer is
coated with the abrasive composition on a first side.
12. The abrasive buff of claim 11, wherein the woven fabric layer
is further coated with the abrasive composition on a second
side.
13. The abrasive buff of claim 1, wherein the abrasive composition
comprises: 20 wt % to 90 wt % of abrasive grains and 10 wt % to 80
wt % of a polymeric binder composition.
14. The abrasive buff of claim 13, wherein the abrasive composition
further comprises: 0.1 wt % to 10 wt % of a rheology modifier.
15. The abrasive buff of claim 14 wherein the rheology modifier
comprises a cellulose compound, a fumed silica, or a combination
thereof.
16. The abrasive buff of claim 12, wherein the abrasive composition
is disposed through the fabric between the yarns from the first
side of the fabric to the second side of the fabric.
17. The abrasive buff of claim 12, wherein the abrasive composition
is disposed between the fibers of the woven fabric layer.
18. The abrasive buff of claim 1, wherein the polymeric binder is
flexible.
19. The abrasive buff of claim 1, wherein the polymeric binder has
a glass transition temperature (Tg) of not greater than 10.degree.
C.
20. An abrasive buff comprising: a plurality of fabric layers; and
an abrasive composition fixed to each of the fabric layers, wherein
the abrasive composition is disposed at least partially within each
of the fabric layers, wherein the abrasive composition comprises a
polymeric binder and a plurality of abrasive particles dispersed in
the polymeric binder, and wherein the polymeric binder the
polymeric binder has a glass transition temperature (Tg) of not
greater than 10.degree. C.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Patent Application No. 62/441,216
entitled "Abrasive Buffing Articles", by Jianna Wang, Ying Cai,
Mike D. Shappell, and Shu Yang, filed Dec. 31, 2016, which is
assigned to the current assignee hereof and incorporated herein by
reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present inventive embodiments relate to abrasive buffing
articles ("abrasive buffs") and methods of making the same. The
abrasive buffs include a substrate, such as a fabric, that has been
impregnated with an abrasive polymeric composition that includes
abrasive particles, such as spray dried abrasive aggregates. The
abrasive buffs are flexible and capable of conforming to and
effectively abrading, polishing, and buffing workpieces possessing
a complex geometry.
BACKGROUND
[0003] Conventional buffs and buffing wheels (collectively referred
to herein as "buffs") are used to polish parts made of metal,
plastic, ceramic, glass, wood, stone, silicon, an optical
materials, among others. Buffing is a finishing process which is
typically accomplished a more rigorous stock removal treatment of a
surface.
[0004] Buffs are frequently categorized as either "cut" buffs or
"color" buffs. A "cut" buff is more aggressive and is typically
employed with a coarser buffing compound, a medium to high pressure
between the buff and the work piece, and the work piece is advanced
against the direction of rotation of the buff. This results in the
refinement of scratches on the work piece and yields a uniform
matte finish. In contrast, a "color" buff is typically employed
with a finer buffing compound, a medium to low pressure between the
buff and the work piece, and the work piece is advanced in the
direction of rotation of the buff. Application of a color buff
results in a further refinement of scratches in the surface of the
work piece and yields a reflective, mirror-like finish.
[0005] Conventional buffs are typically free of any fixed abrasive
material. Instead, abrasive emulsions or solid waxy abrasive
compounds are externally applied to the working surface of the
buff, and periodically reapplied, during abrasive operations.
Conventional buffing systems have various draw backs including high
costs of maintaining and cleaning the abrasive compound transport
and application systems, high material waste during buffing
processes, and costs and concerns associated with disposal of
abrasive compounds.
[0006] Therefore, there continues to be a demand for improved
abrasive products and methods that can offer enhanced abrasive
processing performance, efficiency, and improved surface
quality.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Embodiments are illustrated by way of example and are not
limited in the accompanying figures.
[0008] FIG. 1 is an image of an abrasive buff according to an
embodiment.
[0009] FIG. 2A is an image of an abrasive buff ("Airway buff")
according to an embodiment.
[0010] FIG. 2B is an image of an abrasive buff ("Pleated buff")
according to an embodiment.
[0011] FIG. 2C is an image of an abrasive buff ("Finger buff")
according to an embodiment.
[0012] FIG. 2D is an image of an abrasive buff ("Spiral sewn buff")
according to an embodiment.
[0013] FIG. 2E is an image of an abrasive buff ("String buff")
according to an embodiment.
[0014] FIG. 3 is a process flow diagram of a method of making an
abrasive buff according to an embodiment.
[0015] FIG. 4 is an illustration of a woven fabric substrate being
dip coated with an abrasive composition according to an
embodiment.
[0016] FIG. 5A is an image of a woven fabric substrate according to
an embodiment.
[0017] FIG. 5B is a magnified image of the same woven fabric shown
in FIG. 5A.
[0018] FIG. 6A is an image of an abrasive composition (abrasive
grains in a polymeric binder composition) disposed on a surface of
a woven fabric substrate of an abrasive buff where the abrasive
grains penetrate into and between the fibers of the woven fabric
substrate according to an embodiment.
[0019] FIG. 6B is a cross sectional image of the same embodiment
shown in FIG. 6A and shows that the abrasive composition is
disposed on both surfaces (i.e., the front and the back) of the
woven fabric substrate and the abrasive grains penetrating into and
between the fibers of the woven fabric.
[0020] FIG. 7A is an image of an abrasive composition (abrasive
grains in a polymeric binder composition) disposed on a surface of
a woven fabric substrate of an abrasive buff where the abrasive
grains penetrate into and between the fibers of the woven fabric
substrate according to an embodiment.
[0021] FIG. 7B is a cross sectional image of the same embodiment
shown in FIG. 7A and shows that the abrasive composition is
disposed on both surfaces of the woven fabric substrate and the
abrasive grains penetrating into and between the fibers of the
woven fabric.
[0022] FIG. 8A is an image of an abrasive composition (abrasive
grains in a polymeric binder composition) disposed on a surface of
a woven fabric substrate of an abrasive buff where the abrasive
grains penetrate into and between the fibers of the woven fabric
substrate according to an embodiment.
[0023] FIG. 8B is a cross sectional image of the same embodiment
shown in FIG. 8A and shows that the abrasive composition is
disposed on both surfaces of the woven fabric substrate and the
abrasive grains penetrating into and between the fibers of the
woven fabric.
[0024] FIG. 9A is an image of an abrasive composition (abrasive
grains in a polymeric binder composition) disposed on a surface of
a woven fabric substrate of an abrasive buff where the abrasive
grains penetrate into and between the fibers of the woven fabric
substrate according to an embodiment.
[0025] FIG. 9B is a cross sectional image of the same embodiment
shown in FIG. 9A and shows that the abrasive composition is
disposed on both surfaces of the woven fabric substrate and the
abrasive grains penetrating into and between the fibers of the
woven fabric.
[0026] FIG. 10A is an image of an abrasive composition (abrasive
grains in a polymeric binder composition) disposed on a surface of
a woven fabric substrate of an abrasive buff where the abrasive
grains penetrate into and between the fibers of the woven fabric
substrate according to an embodiment.
[0027] FIG. 10B is a cross sectional image of the same embodiment
shown in FIG. 10A and shows that the abrasive composition is
disposed on both surfaces of the woven fabric substrate and the
abrasive grains penetrating into and between the fibers of the
woven fabric.
[0028] FIG. 11A is an image of an abrasive composition (abrasive
grains in a polymeric binder composition) disposed on a surface of
a woven fabric substrate of an abrasive buff where the abrasive
grains penetrate into and between the fibers of the woven fabric
substrate according to an embodiment.
[0029] FIG. 11B is a cross sectional image of the same embodiment
shown in FIG. 11A and shows that the abrasive composition is
disposed on both surfaces of the woven fabric substrate and the
abrasive grains penetrating into and between the fibers of the
woven fabric.
[0030] FIG. 12A is an image of an abrasive buff according to an
embodiment.
[0031] FIG. 12B is an image of a side view of the abrasive buff of
FIG. 12A showing multiple plies (6-ply) of the abrasive woven
fabric according to an embodiment.
[0032] FIG. 13A is an image of an abrasive buff according to an
embodiment.
[0033] FIG. 13B is an image of a side view of the abrasive buff of
FIG. 13A showing multiple plies (12-ply) of the abrasive woven
fabric according to an embodiment.
[0034] FIG. 13C is an image of a somaparative abrasive buff and
fixed abrasive buffs according to embodiments.
[0035] FIG. 14 is an image showing an abrasive buff according to an
embodiment set up to conduct abrasive testing of the woven abrasive
article.
[0036] FIG. 15 is an illustration of the set up to conduct 5 Degree
Angle testing on a work piece.
[0037] FIG. 16A is a graph comparing gloss (20.degree.) performance
of a conventional manual buffing process (conventional buffing
article and conventional bar/stick abrasive) to an automated
buffing process using an inventive buffing article according to an
embodiment.
[0038] FIG. 16B is a graph comparing surface finish (Ra)
performance of a conventional manual buffing process (conventional
buff and conventional bar/stick abrasive) to an automated buffing
process using an inventive buff according to an embodiment.
[0039] FIG. 16C is a graph comparing power (hp) consumption of a
conventional manual buffing process (conventional buff and
conventional bar/stick abrasive) to an automated buffing process
using an inventive buff according to an embodiment.
[0040] FIG. 16D is a graph comparing surface finish (Rz)
performance of a conventional manual buffing process (conventional
buff and conventional bar/stick abrasive) to an automated buffing
process using an inventive buff according to an embodiment.
[0041] FIG. 17A is a graph comparing gloss (20.degree.) performance
of a conventional manual buffing process (conventional buff and
conventional bar/stick abrasive) to an automated buffing process
using an inventive buff according to an embodiment.
[0042] FIG. 17B is a graph comparing surface finish (Ra)
performance of a conventional manual buffing process (conventional
buff and conventional bar/stick abrasive) to an automated buffing
process using an inventive buff according to an embodiment.
[0043] FIG. 17C is a graph comparing power (hp) consumption of a
conventional manual buffing process (conventional buff and
conventional bar/stick abrasive) to an automated buffing process
using an inventive buff according to an embodiment.
[0044] FIG. 17D is a graph comparing surface finish (Rz)
performance of a conventional manual buffing process (conventional
buff and conventional bar/stick abrasive) to an automated buffing
process using an inventive buff according to an embodiment.
[0045] FIG. 18A is a graph comparing gloss (20.degree.) performance
of a conventional manual buffing process (conventional buff and
conventional bar/stick abrasive) to an automated buffing process
using an inventive buff according to an embodiment.
[0046] FIG. 18B is a graph comparing surface finish (Ra)
performance of a conventional manual buffing process (conventional
buff and conventional bar/stick abrasive) to an automated buffing
process using an inventive buff according to an embodiment.
[0047] FIG. 18C is a graph comparing power (hp) consumption of a
conventional manual buffing process (conventional buff and
conventional bar/stick abrasive) to an automated buffing process
using an inventive buff according to an embodiment.
[0048] Skilled artisans appreciate that elements in the figures are
illustrated for simplicity and clarity and have not necessarily
been drawn to scale. For example, the dimensions of some of the
elements in the figures may be exaggerated relative to other
elements to help to improve understanding of embodiments of the
invention.
DETAILED DESCRIPTION
[0049] The following description in combination with the figures is
provided to assist in understanding the teachings disclosed herein.
The following discussion will focus on specific implementations and
embodiments of the teachings. This focus is provided to assist in
describing the teachings and should not be interpreted as a
limitation on the scope or applicability of the teachings. However,
other embodiments can be used based on the teachings as disclosed
in this application.
[0050] The terms "comprises," "comprising," "includes,"
"including," "has," "having" or any other variation thereof, are
intended to cover a non-exclusive inclusion. For example, a method,
article, or apparatus that comprises a list of features is not
necessarily limited only to those features but may include other
features not expressly listed or inherent to such method, article,
or apparatus. Further, unless expressly stated to the contrary,
"or" refers to an inclusive-or and not to an exclusive-or. For
example, a condition A or B is satisfied by any one of the
following: A is true (or present) and B is false (or not present),
A is false (or not present) and B is true (or present), and both A
and B are true (or present).
[0051] Also, the use of "a" or "an" is employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
invention. This description should be read to include one, at least
one, or the singular as also including the plural, or vice versa,
unless it is clear that it is meant otherwise. For example, when a
single item is described herein, more than one item may be used in
place of a single item. Similarly, where more than one item is
described herein, a single item may be substituted for that more
than one item.
[0052] As used herein, the term "aggregate" may be used to refer to
a particle made of a plurality of smaller particles that have been
combined in such a manner that it is relatively difficult to
separate or disintegrate the aggregate particle into smaller
particles by the application of pressure or agitation. This is in
contrast to the term "agglomerate," which is used herein to refer
to a particle made up of a plurality of smaller particles that have
been combined in such a manner that it is relatively easy to
separate the agglomerate particle or disintegrate the agglomerate
particle back into smaller particles, such as by the application of
pressure or hand agitation.
[0053] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
materials, methods, and examples are illustrative only and not
intended to be limiting. To the extent not described herein, many
details regarding specific materials and processing acts are
conventional and may be found in textbooks and other sources within
the abrasive arts.
[0054] FIG. 1 shows an image of an embodiment of an abrasive
buffing article (100) ("abrasive buff") comprising: a plurality of
woven fabric layers (102). An abrasive composition is fixed to each
of the fabric layers. Each of the fabric layers comprises a
plurality of yarns, wherein the abrasive composition is disposed at
least partially within the yarns and/or between the yarns. The
abrasive composition comprises a polymeric binder and a plurality
of abrasive particles dispersed in the polymeric binder.
[0055] FIG. 3 shows a process flow diagram of a method 300 of
forming an abrasive buff. Step 302 comprises mixing together a
plurality of abrasive grains and a polymeric binder to form a
precursor composition. In an embodiment, the abrasive grains can
comprise abrasive aggregates. Step 304 comprises impregnating a
woven fabric with the precursor composition. In an embodiment, the
abrasive grains penetrate into and between the fibers of the woven
fabric. In an embodiment, the precursor composition can be disposed
on both surfaces (i.e., the front side and the back side) of the
woven fabric. Step 306 comprises curing the precursor composition
to form an abrasive woven cloth. Step 308 comprises forming the
abrasive woven cloth into an abrasive buff.
[0056] FIG. 6A is an image of a surface of a woven fabric substrate
of an abrasive buff where an abrasive composition (i.e., abrasive
grains dispersed in a polymeric binder composition) is disposed on
and in the fabric such that the abrasive composition (including the
abrasive grains) penetrate into and between the fibers of the woven
fabric substrate according to an embodiment.
[0057] FIG. 6B is a cross sectional image of the same embodiment
shown in FIG. 6A and shows that the abrasive composition is
disposed on both surfaces (i.e., the front side and the back side)
of the woven fabric substrate. The abrasive composition (including
the abrasive grains) is penetrating into and between the fibers of
the woven fabric.
[0058] Abrasive Fabric Composition
[0059] The abrasive fabric of the abrasive buff can comprise
varying amounts of abrasive composition. In an embodiment, the
amount of abrasive composition can comprise as least 30 wt % of the
abrasive fabric, such as at least 35% wt %, at least 38 wt %, at
least 40 wt %, at least 42 wt %, or at least 44 wt % of the
abrasive fabric. In another embodiment, the abrasive composition
can comprise not greater than 85 wt % of the abrasive fabric, such
as not greater than 80 wt %, not greater than 75 wt %, not greater
than 70 wt %, not greater than 65 wt %, not greater than 60 wt %,
or not greater than 55 wt % of the abrasive fabric. The amount of
the abrasive composition can be within a range of any minimum or
maximum value noted above. In a specific embodiment, the amount of
the abrasive composition can comprise from at least 30 wt % to not
greater than 85 wt % of the abrasive fabric, such as at least 35 wt
% to not greater than 80 wt % of the abrasive fabric, such as at
least 40 wt % to not greater than 75 wt % of the abrasive fabric,
such as at least 40 wt % to not greater than 70 wt % of the
abrasive fabric.
[0060] The abrasive fabric of the abrasive buff can comprise
varying amounts of fabric. In an embodiment, the amount of fabric
can comprise as least 10 wt % of the abrasive fabric, such as at
least 15% wt %, at least 20 wt %, at least 25 wt %, at least 30 wt
%, or at least 35 wt % of the abrasive fabric. In another
embodiment, the fabric can comprise not greater than 70 wt % of the
abrasive fabric, such as not greater than 65 wt %, not greater than
60 wt %, not greater than 55 wt %, or not greater than 50 wt % of
the abrasive fabric. The amount of the fabric can be within a range
of any minimum or maximum value noted above. In a specific
embodiment, the amount of the fabric can comprise from at least 15
wt % to not greater than 70 wt % of the abrasive fabric, such as at
least 20 wt % to not greater than 65 wt % of the abrasive
fabric.
[0061] Fabric Layer
[0062] An abrasive buff can comprise a plurality of fabric layers.
In an embodiment, each of the fabric layers can comprise an
abrasive composition fixed to each of the fabric layers. In an
embodiment, the fabric layers can comprise woven fabric layers. In
an embodiment, the abrasive composition can be disposed on a first
side of the woven fabric. In an embodiment, the abrasive
composition is further disposed on a second side of the fabric. In
an embodiment, the woven fabric can comprise a plurality of yarns,
such as warp yarns and weft yarns. In an embodiment, the abrasive
composition can be disposed at least partially within or between
the yarns, such as between the warp and weft yarns. In an
embodiment, the abrasive composition can be further disposed
through the fabric between the yarns from the first side of the
fabric to the second side of the fabric.
[0063] Number of Fabric Layers
[0064] An abrasive buff can comprise a plurality of fabric layers
(also called "plys"). In an embodiment, the number of fabric layers
can be at least 2 layers, such as at least 4 layers, at least 6
layers, at least 8 layers, or at least 10 layers. In another
embodiment, the number of layers can be not greater than 20 layers,
such as not greater than 18 layers, not greater than 16 layers, not
greater than 14 layers, or not greater than 12 layers. The number
of fabric layers can be within a range of any minimum or maximum
value noted above. In a specific embodiment, the number of fabric
layers can comprise from at least 2 layers to not greater than 20
layers, such as from at least 4 layers to not greater than 18
layers, at least 6 layers to not greater than 16 layers, or at
least 8 layers to not greater than 14 layers.
[0065] Weave
[0066] The fabric layer can comprise a woven cloth. In an
embodiment, the woven cloth can comprise one or a plurality of
woven patterns, including a plain weave, a basket weave, a rib
weave, a balanced plain weave, a twill weave, a satin weave, or a
combination thereof.
[0067] Thread Count--Warp
[0068] The thread count of a woven cloth can vary in the warp
direction and vary in the weft direction. In an embodiment, the
woven cloth can comprise at least 50 threads per inch in the warp
direction, such as least 55 threads per inch, at least 60 threads
per inch, at least 65 threads per inch, at least 70 per inch, at
least 75 threads per inch, at least 80 threads per inch, at least
85 threads per inch, or at least 90 threads per inch. In another
embodiment, the woven cloth can comprise not greater than 300
threads per inch, such as not greater than 280 threads per inch,
not greater than 260 threads per inch, not greater than 240 threads
per inch, not greater than 220 threads per inch, or not greater
than 200 threads per inch. The threads per inch can be within a
range of any minimum or maximum value noted above. In a specific
embodiment, the amount of threads per inch can comprise from at
least 50 threads per inch to not greater than 300 threads per inch
in the warp direction, such as from 50 threads per inch to not
greater than 100 threads per inch, or from 100 threads per inch to
not greater than 300 threads per inch.
[0069] Thread Count--Weft
[0070] The thread count of a woven cloth can vary in the weft
direction and vary in the weft direction. In an embodiment, the
woven cloth can comprise at least 50 threads per inch in the weft
direction, such as least 55 threads per inch, at least 60 threads
per inch, at least 65 threads per inch, at least 70 per inch, at
least 75 threads per inch, at least 80 threads per inch, at least
85 threads per inch, or at least 90 threads per inch. In another
embodiment, the woven cloth can comprise not greater than 300
threads per inch, such as not greater than 280 threads per inch,
not greater than 260 threads per inch, not greater than 240 threads
per inch, not greater than 220 threads per inch, or not greater
than 200 threads per inch. The threads per inch can be within a
range of any minimum or maximum value noted above. In a specific
embodiment, the amount of threads per inch can comprise from at
least 50 threads per inch to not greater than 300 threads per inch
in the weft direction, such as from 50 threads per inch to not
greater than 100 threads per inch, or from 100 threads per inch to
not greater than 300 threads per inch.
[0071] Ratio--Warp:Weft
[0072] The ratio of warp threads to weft threads of a woven fabric
layer can vary. In an embodiment, the woven cloth comprises a ratio
of warp threads to weft threads (warp:weft) ranging from 1:6 (e.g.,
50/300 thread count) to 6:1 (e.g., 300/50 thread count), such as
from 1:2 to 2:1, or from 1:1.8 to 1:1.
[0073] Fabric Weight
[0074] The "weight" (mass per area) of a fabric can vary. In an
embodiment, the fabric weight can comprise at least 50 GSM, such as
least 75 GSM, at least 100 GSM, or at least 150 GSM GSM. In another
embodiment, the fabric weight can comprise not greater than 800
GSM, such as not greater than 700 GSM, not greater than 600 GSM,
not greater than 500 GSM, not greater than 400 GSM, not greater
than 300 GSM, not greater than 275 GSM, not greater than 250 GSM,
not greater than 225 GSM, or not greater than 200 GSM. The fabric
weight can be within a range of any minimum or maximum value noted
above. In a specific embodiment, the fabric weight can comprise a
weight of at least 50 grams per square meter ("GSM") to not greater
than 800 GSM, such as at least 100 GSM to not greater than 500
GSM.
[0075] Fabric Type
[0076] The fabric can comprise natural fibers, synthetic fibers, or
a combination thereof. Natural fibers can comprise one or more
natural fibers. In an embodiment, natural fibers can comprise
cellulose, cotton, flax, hemp, jute, ramie, sisal, linen, silk, or
a combination thereof. In another embodiment, natural fibers can
comprise cotton. In a specific embodiment, natural fibers can
consist essentially of cotton. Synthetic fibers can comprise one or
more synthetic fibers. In an embodiment, synthetic fibers can
comprise a polymer, a glass, a metal, a rubber, carbon, or a
combination thereof. In another embodiment, synthetic fibers can
comprise a polymer fiber. In a specific embodiment, a polymer fiber
can comprise nylon, acrylic, olefin, polyester, rayon, modal,
Dyneema, or a combination thereof. In a particular embodiment, a
polymer fiber comprises polyester. In a specific embodiment, a
synthetic fiber can consist essentially of polyester.
[0077] Abrasive Composition (Cured Composition)
[0078] The abrasive buff comprises an abrasive composition fixed to
each of the fabric layers. The abrasive composition can comprise a
plurality of abrasive particles (also called abrasive grains
herein) disposed on or in a polymeric binder. In an embodiment, the
abrasive composition can further comprise a rheology modifier.
[0079] The amount of abrasive particles comprising the abrasive
composition can vary. In an embodiment, the abrasive composition
can comprise at least 20 wt % abrasive particles, such as least 25
wt %, at least 30 wt %, at least 35 wt %, at least 40 wt %, at
least 45 wt %, at least 50 wt %, at least 55 wt %, or at least 60
wt % abrasive particles. In another embodiment, the abrasive
composition can comprise not greater than 90 wt % abrasive
particles, such as not greater than 85 wt %, not greater than 80 wt
%, or not greater than 75 wt % abrasive particles. The abrasive
particles can be within a range of any minimum or maximum value
noted above. In a specific embodiment, the amount of abrasive
particles in the abrasive composition can comprise from at least 20
wt % to not greater than 90 wt %, such as from at least 40 wt % to
not greater than 85 wt %, or from 60 wt % abrasive particles to not
greater than 80 wt % abrasive particles.
[0080] The amount of polymeric binder comprising the abrasive
composition can vary. In an embodiment, the abrasive composition
can comprise at least 10 wt % polymeric binder, such as least 15 wt
%, at least 20 wt %, or at least 25 wt % polymeric binder. In
another embodiment, the abrasive composition can comprise not
greater than 80 wt % polymeric binder, such as not greater than 75
wt %, not greater than 70 wt %, not greater than 65 wt %, not
greater than 60 wt %, not greater than 55 wt %, not greater than 50
wt %, not greater than 40 wt %, not greater than 35 wt %, or not
greater than 30 wt % polymeric binder. The polymeric binder can be
within a range of any minimum or maximum value noted above. In a
specific embodiment, the amount of polymeric binder in the abrasive
composition can comprise from at least 10 wt % to not greater than
80 wt %, such as from at least 15 wt % to not greater than 70 wt %,
or from 20 wt % polymeric binder to not greater than 60 wt %
polymeric binder.
[0081] The amount of rheology modifier (also called a thickener
herein) comprising the abrasive composition can vary. In an
embodiment, the abrasive composition can comprise at least 0.3 wt %
rheology modifier, such as least 0.4 wt %, at least 0.5 wt %, or at
least 0.6 wt % rheology modifier. In another embodiment, the
abrasive composition can comprise not greater than 10 wt % rheology
modifier, such as not greater than 8 wt %, not greater than 6 wt %,
not greater than 4 wt %, or not greater than 2 wt %. The rheology
modifier can be within a range of any minimum or maximum value
noted above. In a specific embodiment, the amount of rheology
modifier in the abrasive composition can comprise from at least 0.3
wt % to not greater than 10 wt %, such as from at least 0.4 wt % to
not greater than 6 wt %.
[0082] Abrasive Particles
[0083] Abrasive particles can include essentially single phase
inorganic materials, such as alumina, silicon carbide, silica,
ceria, and harder, high performance superabrasive particles such as
cubic boron nitride and diamond. Additionally, the abrasive
particles can include composite particulate materials. Such
materials can include aggregates, which can be formed through
slurry processing pathways that include removal of the liquid
carrier through volatilization or evaporation, leaving behind
unfired ("green") aggregates, that can optionally undergo high
temperature treatment (i.e., firing, sintering) to form usable,
fired aggregates. Further, the abrasive regions can include
engineered abrasives including macrostructures and particular
three-dimensional structures. In certain embodiments, the abrasive
particles comprise primary particles, aggregates, or a combination
thereof. In certain embodiments, when the abrasive particles are at
least partially abrasive aggregates, the abrasive aggregates may
comprise unfired abrasive aggregates having a generally spheroidal
or toroidal shape that are formed from a composition of abrasive
grit particles and a nanoparticle binder (Nanozyte aggregates). In
certain embodiments, the aggregates may be hollow and may comprise
an interior space (Nanozyte aggregates).
[0084] In an embodiment, the abrasive particles are blended with a
polymeric binder to form abrasive slurry. Alternatively, the
abrasive particles are applied over the polymeric binder after the
polymeric binder is coated on the backing. Optionally, a functional
powder can be applied over the abrasive regions to prevent the
abrasive regions from sticking to a patterning tooling.
Alternatively, patterns can be formed in the abrasive regions
absent the functional powder.
[0085] The abrasive particles can be formed of any one of or a
combination of abrasive particles, including silica, alumina (fused
or sintered), zirconia, zirconia/alumina oxides, silicon carbide,
garnet, diamond, cubic boron nitride, silicon nitride, ceria,
titanium dioxide, titanium diboride, boron carbide, tin oxide,
tungsten carbide, titanium carbide, iron oxide, chromia, flint,
emery, and Tripoli. For example, the abrasive particles can be
selected from a group consisting of silica, alumina, zirconia,
silicon carbide, silicon nitride, boron nitride, garnet, diamond,
co-fused alumina zirconia, ceria, titanium diboride, boron carbide,
flint, emery, alumina nitride, and a blend thereof. Particular
embodiments have been created by use of dense abrasive particles
comprised principally of alpha-alumina.
[0086] The abrasive grain can also have a particular shape. An
example of such a shape includes a rod, a triangle, a pyramid, a
cone, a solid sphere, a hollow sphere, or the like. Alternatively,
the abrasive grain can be randomly shaped.
[0087] In certain embodiments, a portion of the abrasive particles
of the aggregate component may include a coating of a polymer
component disposed between the abrasive particle and the polymeric
binder. In certain embodiments, the polymer component may be
directly in contact with the abrasive particles.
[0088] Particle Size
[0089] In an embodiment, the abrasive particles can have an average
particle size not greater than 4000 microns, such as not greater
than 2000 microns, such as not greater than about 1500 microns, not
greater than about 1000 microns, not greater than about 750
microns, not greater than about 500 microns, not greater than about
250 microns, not greater than about 100 microns, or not greater
than 50 microns. In another embodiment, the abrasive particle size
can be at least 0.1 microns, such as at least 1 micron, at least 5
microns, at least 6 microns, at least 7 microns, at least 8
microns, at least 9 microns, at least 10 microns, at least 15
microns, at least 20 microns, or at least 25 microns. The average
particle size can be within a range of any minimum or maximum value
noted above. In a specific embodiment, the average particle size
can comprise from at least 1 micron to not greater than 2000
microns, such as from at least 5 microns to not greater than 1000
microns, at least 5 microns to not greater than 750 microns, at
least 6 microns to not greater than 500 microns, at least 7 microns
to not greater than 250 microns, or at least 8 microns to not
greater than 100 microns. The particle size of the abrasive
particles is typically specified to be the longest dimension of the
abrasive particle. Generally, there is a range distribution of
particle sizes. In some instances, the particle size distribution
is tightly controlled.
[0090] Polymeric Binder
[0091] The polymeric binder can be formed of a single polymer or a
blend of polymers. The binder composition can be formed from an
epoxy composition, acrylic composition, a phenolic composition, a
polyurethane composition, a phenolic composition, a polysiloxane
composition, an acrylic latex, or combinations thereof. In
addition, the binder composition can include active filler
particles, as described above, additives, or a combination thereof.
In certain embodiments, the polymeric binder can be flexible.
[0092] The polymeric binder generally includes a polymer matrix,
which binds abrasive particles to the backing or to a compliant
coat, if such a compliant coat is present. Typically, the polymeric
binder is formed of cured polymeric binder. In an embodiment, the
polymeric binder includes a polymer component and a dispersed
phase.
[0093] The polymeric binder can include one or more reaction
constituents or polymer constituents for the preparation of a
polymer. A polymer constituent can include a monomeric molecule, a
polymeric molecule, or a combination thereof. The polymeric binder
can further comprise components selected from the group consisting
of solvents, plasticizers, chain transfer agents, catalysts,
stabilizers, dispersants, curing agents, reaction mediators and
agents for influencing the fluidity of the dispersion.
[0094] The polymer constituents can form thermoplastics or
thermosets. By way of example, the polymer constituents can include
monomers and resins for the formation of polyurethane, polyurea,
polymerized epoxy, polyester, polyimide, polysiloxanes (silicones),
polymerized alkyd, styrene-butadiene rubber,
acrylonitrile-butadiene rubber, polybutadiene, or, in general,
reactive resins for the production of thermoset polymers. Another
example includes an acrylate or a methacrylate polymer constituent.
The precursor polymer constituents are typically curable organic
material (i.e., a polymer monomer or material capable of
polymerizing or crosslinking upon exposure to heat or other sources
of energy, such as electron beam, ultraviolet light, visible light,
etc., or with time upon the addition of a chemical catalyst,
moisture, or other agent which cause the polymer to cure or
polymerize). A precursor polymer constituent example includes a
reactive constituent for the formation of an amino polymer or an
aminoplast polymer, such as alkylated urea-formaldehyde polymer,
melamine-formaldehyde polymer, and alkylated
benzoguanamine-formaldehyde polymer; acrylate polymer including
acrylate and methacrylate polymer, alkyl acrylate, acrylated epoxy,
acrylated urethane, acrylated polyester, acrylated polyether, vinyl
ether, acrylated oil, or acrylated silicone; alkyd polymer such as
urethane alkyd polymer; polyester polymer; reactive urethane
polymer; phenolic polymer such as resole and novolac polymer;
phenolic/latex polymer; epoxy polymer such as bisphenol epoxy
polymer; isocyanate; isocyanurate; polysiloxane polymer including
alkylalkoxysilane polymer; or reactive vinyl polymer. The polymeric
binder can include a monomer, an oligomer, a polymer, or a
combination thereof. In a particular embodiment, the polymeric
binder includes monomers of at least two types of polymers that
when cured can crosslink. For example, the binder formulation can
include epoxy constituents and acrylic constituents that when cured
form an epoxy/acrylic polymer. In a specific embodiment, the
polymeric binder can comprise at least one of a polyurethane, a
phenolic, an acrylic latex, or a combination thereof.
[0095] The polymeric binder can comprise a desirable glass
transition temperature (Tg) that can contribute to beneficial
abrasive properties. In an embodiment, the polymeric binder can
comprise a glass transition temperature (Tg) of not greater than
60.degree. C., not greater than 50.degree. C., not greater than
40.degree. C., not greater than 30.degree. C., not greater than
20.degree. C., not greater than 10.degree. C., not greater than
0.degree. C., or not greater than -1.degree. C. In another
embodiment, the polymeric binder can comprise a glass transition
temperature (Tg) of at least -30.degree. C., at least -25.degree.
C., at least -20.degree. C., or at least -15.degree. C. The glass
transition temperature (Tg) can be within a range of any minimum or
maximum value noted above. In a specific embodiment, the glass
transition temperature (Tg) can comprise from at least -30.degree.
C. to not greater than 30.degree. C., such as from at least
-20.degree. C. to not greater than 20.degree. C.
[0096] Rheology Modifier
[0097] In an embodiment, the abrasive composition can comprise a
rheology modifier. The rheology modifier can comprise a cellulose
compound, a fumed silica, or a combination thereof. In a specific
embodiment, the cellulose compound can comprise a hydroxypropyl
cellulose.
EMBODIMENTS LISTING
Embodiment 1
[0098] An abrasive buff comprising:
[0099] a plurality of woven fabric layers; and
[0100] an abrasive composition fixed to each of the fabric
layers,
[0101] wherein each of the fabric layers comprises a plurality of
yarns,
[0102] wherein the abrasive composition is disposed at least
partially within the yarns, and
[0103] wherein the abrasive composition comprises a polymeric
binder and a plurality of abrasive particles dispersed in the
polymeric binder.
Embodiment 2
[0104] The abrasive buff of embodiment 1, wherein the abrasive
composition comprises:
[0105] 15 wt % to 90 wt % of the abrasive buff.
Embodiment 3
[0106] The abrasive buff of embodiment 1, wherein fabric layers
comprise: 10 wt % to 85 wt % of the abrasive buff.
Embodiment 4
[0107] The abrasive buff of embodiment 1, wherein the fabric layer
comprises a woven cloth.
Embodiment 5
[0108] The abrasive buff of embodiment 4, wherein woven cloth
comprises a thread count in a range from 50 to 300 threads per inch
in the warp direction.
Embodiment 6
[0109] The abrasive buff of embodiment 4, wherein woven cloth
comprises a thread count in a range from 50 to 300 threads per inch
in the weft direction.
Embodiment 7
[0110] The abrasive buff of embodiment 4, wherein woven cloth
comprises a thread count of 50/50 to 300/300.
Embodiment 8
[0111] The abrasive buff of embodiment 4, wherein woven cloth
comprises a ratio of warp thread count to weft thread count ranging
from 1:1.8 to 1:1.
Embodiment 9
[0112] The abrasive buff of embodiment 4, wherein the woven cloth
comprises fibers having a linear density in a range of 0.1 denier
to 500 denier.
Embodiment 10
[0113] The abrasive buff of embodiment 1, wherein the fabric
comprises a weight of grams per square meter ("GSM") in a range of
100 to 800 GSM.
Embodiment 11
[0114] The abrasive buff of embodiment 1, wherein the fabric
comprises synthetic fibers, natural fibers, or a combination
thereof.
Embodiment 12
[0115] The abrasive buff of embodiment 11, wherein the natural
fibers comprise cotton.
Embodiment 13
[0116] The abrasive buff of embodiment 1, wherein the fabric layer
is coated with the abrasive composition on a first side.
Embodiment 14
[0117] The abrasive buff of embodiment 1, wherein the fabric layer
is further coated with the abrasive composition on a second
side.
Embodiment 15
[0118] The abrasive buff of embodiment 1, wherein the abrasive
composition comprises 20 wt % to 90 wt % of abrasive grains.
Embodiment 16
[0119] The abrasive buff of embodiment 1, wherein the abrasive
composition comprises 10 wt % to 80 wt % of a polymeric binder
composition.
Embodiment 17
[0120] The abrasive buff of embodiment 1, wherein the abrasive
composition further comprises a rheology modifier.
Embodiment 18
[0121] The abrasive buff of embodiment 17, wherein the abrasive
composition comprises 0.1 wt % to 10 wt % of the rheology
modifier.
Embodiment 19
[0122] The abrasive buff of embodiment 17, wherein the rheology
modifier comprises a cellulose compound, a fumed silica, or a
combination thereof.
Embodiment 20
[0123] The abrasive buff of embodiment 1, wherein the abrasive
composition is disposed on a first side of the woven fabric.
Embodiment 21
[0124] The abrasive buff of embodiment 20, wherein the abrasive
composition is further disposed on a second side of the fabric.
Embodiment 22
[0125] The abrasive buff of embodiment 21, wherein the abrasive
composition is further disposed through the fabric between the
yarns from the first side of the fabric to the second side of the
fabric.
Embodiment 23
[0126] The abrasive buff of embodiment 22, wherein the abrasive
composition is further disposed between the fibers of the fabric
layer.
Embodiment 24
[0127] The abrasive buff of embodiment 1, wherein the abrasive
particles comprise primary abrasive particles, abrasive aggregates,
or a combination thereof.
Embodiment 25
[0128] The abrasive buff of embodiment 24, wherein the abrasive
particles comprise primary abrasive particles.
Embodiment 26
[0129] The abrasive buff of embodiment 24, wherein the abrasive
particles comprise abrasive aggregates.
Embodiment 27
[0130] The abrasive buff of embodiment 26, wherein the abrasive
aggregates comprise unfired abrasive aggregates having a generally
spheroidal or toroidal shape that are formed from a composition of
abrasive grit particles and a nanoparticle binder.
Embodiment 28
[0131] The abrasive buff of embodiment 27, wherein the aggregates
are hollow and comprise an interior space.
Embodiment 29
[0132] The abrasive buff of embodiment 1, wherein the abrasive
particles comprise silica, silicon carbide, Tripoli, aluminum
oxide, or a combination thereof.
Embodiment 30
[0133] The abrasive buff of embodiment 1, wherein the polymeric
binder is flexible.
Embodiment 31
[0134] The abrasive buff of embodiment 1, wherein the polymeric
binder has a glass transition temperature (Tg) of not greater than
10.degree. C.
Embodiment 32
[0135] The abrasive buff of embodiment 1, wherein polymeric binder
has a glass transition temperature (Tg) in a range of -30.degree.
C. to 60.degree. C.
Embodiment 33
[0136] The abrasive buff of embodiment 1, wherein the polymeric
binder comprises a polyurethane composition, a phenolic
composition, an acrylic latex composition, or a combination
thereof.
Embodiment 34
[0137] An abrasive buff comprising: a plurality of fabric layers;
and an abrasive composition fixed to each of the fabric layers,
wherein the abrasive composition is disposed at least partially
within each of the fabric layers, wherein the abrasive composition
comprises a polymeric binder and a plurality of abrasive particles
dispersed in the polymeric binder, and wherein the polymeric binder
the polymeric binder has a glass transition temperature (Tg) of not
greater than 10.degree. C.
Embodiment 35
[0138] A method of forming a buff wheel comprising:
[0139] providing a fabric substrate; providing an abrasive
composition, the abrasive composition comprising: [0140] a
plurality of abrasive aggregates; and [0141] a polymeric binder; at
least partially impregnating the fabric substrate with the abrasive
composition; and configuring the fabric substrate into a buff
wheel.
Embodiment 36
[0142] A method of forming an abrasive buff comprising:
[0143] mixing together a plurality of abrasive grains and a
polymeric binder to form a precursor composition;
[0144] impregnating a woven fabric with the precursor
composition;
[0145] curing the precursor composition to form an abrasive woven
cloth;
[0146] forming the abrasive woven cloth into an abrasive buff.
Embodiment 37
[0147] The method of forming an abrasive buff of embodiment 36,
wherein the abrasive grains are abrasive aggregates.
Embodiment 38
[0148] The method of forming an abrasive buff of embodiment 35,
wherein the polymeric composition comprises a glass transition
temperature (Tg) of not greater than 10.degree. C.
Embodiment 39
[0149] An abrasive buff comprising:
[0150] a plurality of woven fabric layers; and
[0151] an abrasive composition fixed to each of the fabric
layers,
[0152] wherein each of the fabric layers comprises a plurality of
yarns,
[0153] wherein the abrasive composition is disposed at least
partially within the yarns, and
[0154] wherein the abrasive composition comprises: [0155] a
polymeric binder and [0156] a plurality of abrasive particles
dispersed in the polymeric binder.
Embodiment 40
[0157] The abrasive buff of embodiment 39, wherein the abrasive
composition comprises:
[0158] 15 wt % to 90 wt % of the abrasive buff.
Embodiment 41
[0159] The abrasive buff of embodiment 39, wherein fabric layers
comprise: 10 wt % to 85 wt % of the abrasive buff.
Embodiment 42
[0160] The abrasive buff of embodiment 39, wherein the woven fabric
layer comprises a woven cloth.
Embodiment 43
[0161] The abrasive buff of embodiment 42, wherein the woven cloth
comprises a thread count in a range from 50 to 300 threads per inch
in the warp direction.
Embodiment 44
[0162] The abrasive buff of embodiment 42, wherein the woven cloth
comprises a thread count in a range from 50 to 300 threads per inch
in the weft direction.
Embodiment 45
[0163] The abrasive buff of embodiment 42, wherein woven cloth
comprises a ratio of warp thread count to weft thread count ranging
from 1:1.8 to 1:1.
Embodiment 46
[0164] The abrasive buff of embodiment 42, wherein the woven cloth
comprises fibers having a linear density in a range of 0.1 denier
to 500 denier.
Embodiment 47
[0165] The abrasive buff of embodiment 39, wherein the fabric
comprises a weight of grams per square meter ("GSM") in a range of
100 to 800 GSM.
Embodiment 48
[0166] The abrasive buff of embodiment 39, wherein the fabric
comprises synthetic fibers, natural fibers, or a combination
thereof.
Embodiment 49
[0167] The abrasive buff of embodiment 39, wherein the woven fabric
layer is coated with the abrasive composition on a first side.
Embodiment 50
[0168] The abrasive buff of embodiment 49, wherein the woven fabric
layer is further coated with the abrasive composition on a second
side.
Embodiment 51
[0169] The abrasive buff of embodiment 39, wherein the abrasive
composition comprises:
[0170] 20 wt % to 90 wt % of abrasive grains and
[0171] 10 wt % to 80 wt % of a polymeric binder composition.
Embodiment 52
[0172] The abrasive buff of embodiment 51, wherein the abrasive
composition further comprises: 0.1 wt % to 10 wt % of a rheology
modifier.
Embodiment 53
[0173] The abrasive buff of embodiment 52 wherein the rheology
modifier comprises a cellulose compound, a fumed silica, or a
combination thereof.
Embodiment 54
[0174] The abrasive buff of embodiment 50, wherein the abrasive
composition is disposed through the fabric between the yarns from
the first side of the fabric to the second side of the fabric.
Embodiment 55
[0175] The abrasive buff of embodiment 50, wherein the abrasive
composition is disposed between the fibers of the woven fabric
layer.
Embodiment 56
[0176] The abrasive buff of embodiment 39, wherein the polymeric
binder is flexible.
Embodiment 57
[0177] The abrasive buff of embodiment 39, wherein the polymeric
binder has a glass transition temperature (Tg) of not greater than
10.degree. C.
Embodiment 58
[0178] An abrasive buff comprising:
[0179] a plurality of fabric layers; and
[0180] an abrasive composition fixed to each of the fabric
layers,
[0181] wherein the abrasive composition is disposed at least
partially within each of the fabric layers,
[0182] wherein the abrasive composition comprises a polymeric
binder and a plurality of abrasive particles dispersed in the
polymeric binder, and
[0183] wherein the polymeric binder the polymeric binder has a
glass transition temperature (Tg) of not greater than 10.degree.
C.
EXAMPLES
[0184] The properties and advantage of the present disclosure are
illustrated in further detail in the following nonlimiting
examples. Unless otherwise indicated, temperatures are expressed in
degrees Celsius, pressure is ambient, and concentrations are
expressed in weight percentages.
[0185] Components Listing:
[0186] Green silicon carbide JIS graded: J700, J800, J1000, J1200
from Graystar LLC.
[0187] Hycar.RTM. 26345--acrylic emulsion from Lubrizol Advanced
Materials, Inc.
[0188] Klucel.TM.--M-hydroxypropyl cellulose thickener from
Ashland.
[0189] Aerodisp.RTM. WR8520--fumed silica dispersion thickener from
Evonik Industries.
[0190] Surfynol.RTM. DF70 Defoamer from Air Product.
[0191] Triton 102X Wetting agent from Dow Chemical.
[0192] Greige Cloth from Garfield Buff Company. The cloth has
thread count of 90/76, cloth weight is 12.3 lbs./ream.
[0193] Double Ground Tripoli Rose
[0194] Nanozyte unfired aggregates of white aluminum oxide J1000
grit
[0195] White aluminum oxide J1200
Example 1--Preparation of Abrasive Compositions (Samples S1-S8)
[0196] Sample abrasive compositions S1-S4 having different types
and amounts of abrasive particles and polymeric binder were
prepared using the formulations listed in Table 1. Additional
sample abrasive compositions S5-S8 having different types and
amounts of abrasive particles and polymeric binder were prepared
using the formulations listed in Table 2. The components were
thoroughly mixed together and the resulting compositions were
stored for later use.
TABLE-US-00001 TABLE 1 Abrasive Composition Formulation S1-S4 S1 S1
S2 S2 S3 S3 S4 S4 % Wet % Dry % Wet % Dry % Wet % Dry % Wet % Dry
Hycar 26345 24.6 24.5 24.6 24.5 24.6 24.5 24.6 24.5 Green SiC 37.2
73.9 -- -- -- -- -- -- J1200 Green SiC -- -- 37.2 73.9 -- -- -- --
J1000 Green SiC -- -- -- -- 37.2 73.9 -- -- J800 Green SiC -- -- --
-- -- -- 37.2 73.9 J700 Water 24.1 -- 24.2 -- 24.1 -- 24.6 -- 6%
Klucel 13.7 1.6 13.7 1.6 13.7 1.6 13.7 1.6 Wet Agent .2 -- .2 -- .2
-- .2 -- Triton 102X DF70 .2 -- .2 -- .2 -- .2 -- Total 100 100 100
100 100 100 100 100
TABLE-US-00002 TABLE 2 Abrasive Composition Formulation S5-S8 S5 S5
S6 S6 S7 S7 S8 S8 % Wet % Dry % Wet % Dry % Wet % Dry % Wet % Dry
Hycar 26345 24.9 24.7 24.9 24.7 24.8 24.6 24.9 24.7 Green SiC 37.7
74.6 -- -- -- -- -- -- J1200 Double Ground -- -- 37.7 74.6 -- -- --
-- Tripoli Rose Nanozyte -- -- -- -- 37.6 74.4 -- -- WA1000 WA
J1200, -- -- -- -- -- -- 37.7 74.6 9.5mu Water 30.9 -- 30.9 -- 29.3
-- 35.1 -- 6% Klucel 6.5 0.7 6.5 0.7 8.3 1.0 -- -- 17% Klucel -- --
-- -- -- -- 2.3 0.7 Total 100 100 100 100 100 100 100 100
Example 2--Preparation of Abrasive Cloth (Samples S1-S8)
[0197] The sample abrasive compositions S1-S8 were used to prepare
abrasive cloth. An uncoated "blank" 100% cotton Greige cloth
(thread count 90/76, cloth weight 182 GSM) was unwound from a roll
and dipped in the sample abrasive compositions using a dip tank. A
portion of the uncoated Greige cloth was used as a control (C1).
FIGS. 5A and 5B show the uncoated cloth C1. The dipped cloth was
run through metering rolls to remove excess liquid. FIG. 4 shows an
embodiment of the dipping step. The impregnated fabric was passed
through an oven to cure the abrasive composition. The cured
abrasive cloth was collected on a winding station for further
processing. Abrasive sample cloths S1-S4 were produced as
described. A second uncoated "blank" 100% cotton Greige cloth
served as a second control (C2) and was used to produce sample
abrasive cloth samples S5-S8. A portion of the sample abrasive
cloths were cut into 3-inch OD circles ("discs") for fabric
analysis. The results of the testing are shown in Table 3. It was
noted that all the completed samples S1-S8 were "soft" to the touch
and retained their flexibility, "hand," and "drape."
TABLE-US-00003 TABLE 3 Sample Abrasive Cloth (S1-S4) Cured Add-On
Abrasive Composition Abrasive Sample Disc Total Weight Cloth
Composition 3'' OD round Weight (g) (g) (wt %) (wt %) Control 1 0.8
0.0 100% 0% (Blank Cloth) S1 1.6 0.8 52% 48% S2 1.4 0.6 59% 41% S3
1.4 0.6 59% 41% S4 1.5 0.7 55% 45% Control 2 0.7 0.0 100% 0% (Blank
Cloth) S5 1.5 0.8 46% 54% S6 1.5 0.8 47% 53% S7 1.7 1.0 42% 58% S8
1.5 0.8 48% 52%
[0198] FIGS. 5A and 5B show images of uncoated control C1. FIGS. 6A
and 6B show images of abrasive cloth sample S5. FIGS. 7A and 7B
show images of abrasive cloth sample S6. FIGS. 8A and 8B show
images of abrasive cloth sample S1. FIGS. 9A and 9B show images of
abrasive cloth sample S2. FIGS. 10A and 10B show images of abrasive
cloth sample S3. FIGS. 11A and 11B show images of abrasive cloth
sample S4.
Example 3--Preparation of Abrasive Buffs (Samples S5-S8)
[0199] Buff wheels were created according to conventional methods
(Garfield Buff Company, Fairfield, N.J.). The sample abrasive
cloths were tucked into a metal clinch ring and a metal plate with
center ("arbor") hole was inserted. The buff wheel specifications
were: 8 plys, 8'' OD, 3'' ID, arbor hole 1.5''. An exemplary sample
buff wheel is shown in FIG. 1. FIGS. 12A and 12 B show sample
pleated buffs. FIG. 13A and FIG. 13B show sample airway buffs. FIG.
13C shows sample airway buffs (wheel specifications: 8 plys, 8''
OD, 3'' ID, arbor hole 1.5'') comprising sample abrasive fabrics
S5-S7 and control C2.
Example 4. Abrasive Testing of Buffs
[0200] Abrasive testing of sample fixed abrasive buffs S5-S8 was
conducted on an automated Elb surface grinder. The goal was to
investigate the polishing and wear behavior of the fixed abrasive
buffs in an automated process compared to traditional bar compound
buffing by hand. FIG. 14 displays the automated test setup.
[0201] Test workpieces were blocks of 304SS measuring
8''.times.4''.times.1''. Testing was directed to surface finish
refinement and surface gloss improvement of rough workpiece. The
initial surface of the workpieces were pre-ground with either a
grinding wheel (surface "A") or a grinding belt (surface "B") to an
initial surface roughness Ra of 15-20 .mu.inches. It is generally
believed that a grinding wheel tends to leave deeper surface
features in a surface than a belt and both methods were used to
better simulate a variety of field conditions.
[0202] For comparison, one 304SS part from the field was used for
comparison with the automated buffing results. The comparative part
was then manually buffed with a conventional Tripoli bar compound.
The surface finish and surface gloss of both sides of the workpiece
were measured. Buffing was conducted at a 5.degree. angle from the
grinding marks as shown in FIG. 15.
[0203] Sample inventive fixed abrasive buffs were tested against
the conventional method of buffing (i.e., buffing with an uncoated
buff and periodically applying traditional Tripoli bar compound to
the buff surface during buffing).
[0204] FIGS. 16A, 16B, 16C, and 16D show surface gloss
(20.degree.), surface finish (Ra), power draw (hp), and surface
finish (Rz) for inventive sample buffs S5 compared to control buff
C2 on surface "A" workpieces. Sample buff S5 was first tested under
dry conditions at 7500 SFPM for about a minute (S5 Dry A) and then
water was sprayed onto the buff to cool the buffing process.
Buffing was continued at 7500 SFPM (S5 Wet A). Additionally,
another sample S5 buff was tested on a surface "B" workpiece under
water spray conditions (S5 Wet B). Unexpectedly and beneficially,
improved gloss performance was achieved by the inventive fixed
abrasive sample buffs compared to the conventional method and buff
C2.
[0205] Similar abrasive testing was conducted for control buff C2
and inventive sample buffs S5, S6, and S7. FIGS. 17A, 17B, 17C, and
17D show surface gloss (20.degree.), surface finish (Ra), power
draw (hp), and surface finish (Rz) for inventive sample buffs S6
compared to control buff C2 on workpieces having the same surface
roughness type. Sample buff S6 was first tested under dry
conditions at 7500 SFPM (S6 Dry 7500 rpm), then under dry
conditions at 9000 SFRPM (S6 Dry 9000), and then water was sprayed
onto the buff to cool the remainder of the buffing process (S6 Wet
9000). Again, unexpected and beneficially improved gloss
performance was achieved by the inventive fixed abrasive sample
buffs compared to the conventional buff C2.
[0206] FIGS. 18A, 18B, and 18C show bar graphs displaying surface
gloss (20.degree.), surface finish (Ra), and surface finish (Rz)
comparisons for inventive abrasive buff samples S5, S6, and S7
compared to control buff C2. All inventive sample buffs achieved
improved gloss performance and comparable surface roughness.
[0207] The specification and illustrations of the embodiments
described herein are intended to provide a general understanding of
the structure of the various embodiments. The specification and
illustrations are not intended to serve as an exhaustive and
comprehensive description of all of the elements and features of
apparatus and systems that use the structures or methods described
herein. Separate embodiments may also be provided in combination in
a single embodiment, and conversely, various features that are, for
brevity, described in the context of a single embodiment, may also
be provided separately or in any subcombination. Further, reference
to values stated in ranges includes each and every value within
that range. Many other embodiments may be apparent to skilled
artisans only after reading this specification. Other embodiments
may be used and derived from the disclosure, such that a structural
substitution, logical substitution, or another change may be made
without departing from the scope of the disclosure. Accordingly,
the disclosure is to be regarded as illustrative rather than
restrictive.
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