JP5238726B2 - Abrasive article and method for producing and using the same - Google Patents

Abstract

An abrasive article comprises a porous abrasive member, a nonwoven filter medium, a second nonwoven filter medium, and optionally a porous attachment layer. A plurality of openings in the porous abrasive member cooperates with the first nonwoven filter medium to allow the flow of particles from an outer abrasive surface of the porous abrasive member to the second nonwoven filter medium. Methods of making and using the abrasive articles are included.

Description

  Abrasive articles are used in the industry for polishing, grinding, and polishing applications.

  These are available in variously modified shapes such as many different sized belts, disks, sheets and the like.

  Generally, when the abrasive article is used in the form of “sheet products” (ie, discs or sheets), a backup pad is used to attach or attach the abrasive article to the abrasive tool. Some backup pads have dust collection holes connected by a series of grooves. Dust collection holes are typically connected to a vacuum source, eg, swarf that accumulates on the polishing surface of an abrasive article (as used herein, the term “swarf” is used during the polishing process. It is useful for controlling particles such as dust and debris generated in It is known that the performance of abrasive articles is improved by removing shavings from the abrasive surface.

  Some polishing tools have integrated vacuum systems equipped with dust collection means. The extraction and retention capabilities of these abrasive tools are limited to some extent due to the suction requirements of existing abrasive discs required for their associated backup pads.

US Reissue Patent No. 30,782 US Reissue Patent No. 31,285 US Pat. No. 5,496,507 US Pat. No. 5,472,481 U.S. Pat. No. 4,215,682 US Pat. No. 5,057,710 US Pat. No. 4,592,815 US Patent No. 5,976,208 US Pat. No. 6,139,308 US Pat. No. 5,496,507 US Pat. No. 5,058,247 U.S. Pat. No. 4,894,060 US Pat. No. 5,679,302 US Pat. No. 6,579,161 US Patent Application Publication No. 2004/0170801

  In some polishing tool configurations, dust is collected into the composite dust collection system through a hose connected to the polishing tools. However, the operator of the polishing tool cannot always use the dust collection system. In addition, the use of dust collection systems that require a hose can be cumbersome and can prevent the operator from operating the polishing tool.

In one aspect, the invention is an abrasive article comprising:
A porous abrasive member comprising an abrasive layer secured adjacent to a first surface of a substrate, wherein the abrasive layer is secured to the first surface of the substrate by at least one binder. Comprising abrasive particles, the abrasive layer has an outer polishing surface, the substrate has a second surface opposite to the first surface of the substrate, and the plurality of openings are A porous abrasive member extending from the outer abrasive surface to the second surface of the substrate and comprising a perforated coated abrasive or a coated screen abrasive ;
A first nonwoven fabric having a first surface and a second surface opposite to the first surface, wherein the first surface of the first nonwoven fabric is fixed adjacent to the second surface of the substrate. A first nonwoven filter medium, wherein the first nonwoven filter medium includes a plurality of fibers;
A second nonwoven filter medium having a first surface and a second surface opposite to the first surface, the first surface of the second nonwoven filter medium being fixed adjacent to the second surface of the first nonwoven filter medium A second nonwoven filter medium, wherein the second nonwoven filter medium includes a plurality of fibers, and
Through the plurality of openings and the first nonwoven filter medium, a flow of particles from the outer polishing surface toward the second nonwoven filter medium is generated, and in an unused state, at least a part of the abrasive article contains 0.2 to 20 water. An abrasive article is provided that exhibits a pressure drop that conforms to pressure drop measurement tests in the milliliter range.

In another aspect, the present invention is a method of manufacturing an abrasive article comprising:
Providing a porous abrasive member comprising an abrasive layer secured adjacent to a first surface of a substrate, wherein the abrasive layer is secured to the first surface of the substrate by at least one binder. A plurality of abrasive particles, the abrasive layer has an outer polishing surface, the substrate has a second surface opposite to the first surface of the substrate, The opening extends from the outer polishing surface to the second surface of the substrate , wherein the pre-porous abrasive member comprises a perforated coated abrasive or a coated screen abrasive ;
A step of providing a first nonwoven filter medium, wherein the first nonwoven filter medium has a first surface and a second surface opposite to the first surface, and the first nonwoven filter medium includes a plurality of fibers. And wherein the first surface of the first nonwoven filter medium is adjacent to the second surface of the substrate;
A step of providing a second nonwoven filter medium, wherein the second nonwoven filter medium has a first surface and a second surface opposite to the first surface, and the second nonwoven filter medium contains a plurality of fibers. The first surface of the second nonwoven filter medium is adjacent to the second surface of the first nonwoven filter medium; and
Fixing the first nonwoven filter medium to the second surface of the substrate;
Fixing the second nonwoven filter medium to the first nonwoven filter medium,
Through the plurality of openings and the first nonwoven filter medium, a flow of particles from the outer polishing surface toward the second nonwoven filter medium is generated, and in an unused state, at least a part of the abrasive article has a water content of 0.2 to 0.2. A manufacturing method is provided that exhibits a pressure drop that conforms to pressure drop measurement tests in the range of up to 20 milliliters.

In yet another aspect, the present invention is an abrasive article comprising:
A porous abrasive member comprising an abrasive layer secured adjacent to a first surface of a substrate, wherein the abrasive layer is secured to the first surface of the substrate by at least one binder. Comprising abrasive particles, the abrasive layer has an outer polishing surface, the substrate has a second surface opposite to the first surface of the substrate, and the plurality of openings are A porous abrasive member extending from the outer abrasive surface to the second surface of the substrate;
A first nonwoven fabric having a first surface and a second surface opposite to the first surface, wherein the first surface of the first nonwoven fabric is fixed adjacent to the second surface of the substrate. A first nonwoven filter medium comprising a plurality of fibers, the first nonwoven filter medium having a thickness of 1 to 25 millimeters and a bulk density of 0.04 to 0.5 grams / cubic centimeter;
A second nonwoven filter medium having a first surface and a second surface opposite to the first surface, the first surface of the second nonwoven filter medium being fixed adjacent to the second surface of the first nonwoven filter medium A second nonwoven filter medium, wherein the second nonwoven filter medium comprises a plurality of fibers, the second nonwoven filter medium having a thickness of 0.5 to 15 millimeters and a bulk density of 0.04 to 0.5 grams / cubic centimeter; Including,
Provided is an abrasive article in which a plurality of openings cooperate with the first nonwoven filter medium to cause a flow of particles from the outer polishing surface toward the second nonwoven filter medium.

In yet another aspect, the present invention is a method of manufacturing an abrasive article comprising:
Providing a porous abrasive member comprising an abrasive layer secured adjacent to a first surface of a substrate, wherein the abrasive layer is secured to the first surface of the substrate by at least one binder. A plurality of abrasive particles, the abrasive layer has an outer polishing surface, the substrate has a second surface opposite to the first surface of the substrate, The opening extends from the outer polishing surface to the second surface of the substrate; and
Providing a first nonwoven filter medium having a first surface and a second surface opposite the first surface, wherein the first surface of the first nonwoven filter medium is adjacent to the second surface of the substrate. The first nonwoven filter medium includes a plurality of fibers, and the second nonwoven filter medium has a thickness of 0.5 to 15 millimeters and a bulk density of 0.04 to 0.5 grams / cubic centimeter;
A step of providing a second nonwoven filter medium having a first surface and a second surface opposite to the first surface, wherein the first surface of the second nonwoven filter medium is a second surface of the first nonwoven filter medium; Adjacent, the second nonwoven filter medium includes a plurality of fibers, and the second nonwoven filter medium has a thickness of 0.5 to 15 millimeters and a bulk density of 0.04 to 0.5 grams / cubic centimeter; ,
Fixing the first nonwoven filter medium to the second surface of the substrate; and
Adhering the second nonwoven filter medium to the first nonwoven filter medium, and
Provided is a manufacturing method in which a plurality of openings cooperate with the first nonwoven fabric to cause a flow of particles from the outer polishing surface toward the second nonwoven fabric.

  In certain embodiments, the porous abrasive member comprises a perforated coated abrasive. In certain embodiments, the porous abrasive member includes a screen abrasive. In certain embodiments, the first nonwoven filter medium and the second nonwoven filter medium are secured to each other by needle tacking or stitch bonding. In certain embodiments, the porous abrasive member is secured to the first nonwoven filter medium with an adhesive. In certain embodiments, the first nonwoven filter medium is secured to the second nonwoven filter medium with an adhesive. In certain embodiments, at least one of the first nonwoven filter medium or the second nonwoven filter medium includes synthetic fibers selected from the group consisting of propylene fibers, polyester fibers, nylon fibers, and mixtures thereof. In certain embodiments, the substrate is selected from the group consisting of metal foil, paper, fabric, and plastic film. In certain embodiments, at least one of the first nonwoven filter medium or the second nonwoven filter medium comprises a blown microfiber web. In certain embodiments, at least one of the first nonwoven filter medium or the second nonwoven filter medium includes an electret charge. In certain embodiments, the second surface of the substrate and the first surface of the first nonwoven filter medium have the same extent, the second surface of the first nonwoven filter medium and the first surface of the second nonwoven filter medium, Have the same extent. In certain embodiments, at least one of the first nonwoven filter medium or the second nonwoven filter medium has a peripheral edge sealed along its major portion. In certain embodiments, the abrasive article includes an abrasive disc.

  In certain embodiments, the porous bonding layer is secured to the second surface of the second nonwoven filter medium. In certain embodiments, the porous bonding layer comprises a loop or hook portion of a two-part mechanical engagement system. In a specific embodiment, the first nonwoven filter medium, the second nonwoven filter medium, and the porous bonding layer are fixed to each other by needle tacking or stitch bonding.

  An abrasive article according to the present invention polishes a workpiece surface by a method including, for example, contacting the workpiece surface with the abrasive article and mechanically modifying the surface by moving the abrasive article relative to the surface. Useful for.

  Advantageously, the abrasive articles according to the present invention are particularly suitable for use in these abrasive applications that generate substantial amounts of particles (eg, shavings), and in at least some embodiments, for example, Effectively use at least 40%, 50% (ie, majority), 60%, 70%, 80%, or more than 90% of the particles generated in such abrasive applications when used in combination with a tool having a vacuum source Can be captured.

As used herein,
The term “air resistance” refers to the resistance of air through the thickness dimension of a nonwoven web or abrasive article, and when used for comparison purposes, all air resistance values should be measured under the same conditions;
The term “nonwoven filter media” refers to a material that has internal voids and that is substantially formed from a plurality of entangled and / or bonded fibers and that is manufactured by a method other than weaving or knitting; and The term “thickness” as applied to nonwoven filter media is ASTM D5736-95 (revised 2001) “Standard Test Method for Thickness of Highloft Nonwoven Fabrics”. Refers to the thickness of the nonwoven web as measured using a pressure plate force of 13.8 Pa (0.002 pounds per square inch).

1 is a perspective view of a representative abrasive article according to an embodiment of the present invention, with a portion cut away to show the layers forming the article. FIG. FIG. 1B is a schematic cross-sectional view of the abrasive article shown in FIG. 1A. 1 is a plan view of a representative porous abrasive member useful in an abrasive article according to the present invention. FIG. 2B is a cross-sectional view of the porous polishing member shown in FIG. 2A. 1 is a plan view with a portion cut away to show the components forming an abrasive layer of a representative porous abrasive member useful in an abrasive article according to the present invention. FIG. 1 is a full-scale plan view showing an exemplary drilling pattern 400 for a 12.7 cm (5 inch) diameter coated abrasive disc.

  These figures are idealized and are merely intended to illustrate the abrasive article of the present invention and are non-limiting.

  FIG. 1A shows a perspective view of a representative abrasive article 102 (shown as an abrasive disc) with a portion cut away. As shown in FIG. 1A, the abrasive article 102 includes a porous abrasive member 104, a first nonwoven filter medium 120, a second nonwoven filter medium 140, and an optional porous bonding layer 146. The porous polishing member 104 includes a plurality of openings through which particles (for example, chips generated during the polishing process) flow through the porous polishing member 104. The particles are captured by the filter media in the abrasive article. The optional seals 105 seal the peripheral edges 106 (shown in FIG. 1B) of the first and second nonwoven filter media 120 and 140, respectively, so that particles that are not held by the abrasive article 102 flow laterally. To prevent.

  FIG. 1B shows a schematic cross-sectional view of the abrasive article 102 shown in FIG. 1A. As shown in FIG. 1B, the abrasive article 102 includes a plurality of layers. The first nonwoven filter medium 120 includes a first surface 122 and a second surface 124 opposite to the first surface 122. The second nonwoven filter medium 140 includes a first surface 142 and a second surface 144 opposite to the first surface 142. The first surface 122 of the first nonwoven filter medium 120 is adjacent to the porous polishing member 104. The second surface 124 of the first nonwoven filter medium 120 is adjacent to the first surface 142 of the second nonwoven filter medium 140. The porous bonding layer 146 is adjacent to the second surface 144 of the second nonwoven filter medium 140.

  The porous abrasive member of the abrasive article and the various filter media layers are secured together in a manner that does not prevent the flow of particles from one layer to the next, but the particle flow is present in part or in trace amounts. There is also a case. In some embodiments, the porous abrasive member and the various filter media layers of the abrasive article are secured together in a manner that does not substantially inhibit the flow of particles from one layer to the next. In some embodiments, the amount of particles flowing through the abrasive article is such that the abrasive is introduced between the porous abrasive member and the first nonwoven filter medium or between the first nonwoven filter medium and the second nonwoven filter medium. Can also be at least partially limited. The degree of restriction can be, for example, a non-continuous type such as a separate bond area (eg spray spray or starved extrusion die) or individual bond lines (eg hot melt rotating spray or patterned roll coater). Thus, it can be minimized by applying an adhesive between the layers.

  FIG. 2A shows a plan view of an exemplary coated abrasive used to form a porous abrasive member. FIG. 2B shows a cross-sectional view of a portion of the porous abrasive member shown in FIG. 2A. As shown in FIG. 2B, the porous abrasive member 204 includes a substrate 206 having a first surface 208 and a second surface 210, a make coat 214, a plurality of abrasive particles 212, a size coat 215, including. As shown in FIG. 2A, the porous abrasive member 204 includes a plurality of openings 216 (not shown in FIG. 2B).

  FIG. 3 shows a plan view of a typical screen abrasive used to form a porous abrasive member. FIG. 3 includes a portion cut away to show the components forming the abrasive layer. As shown in FIG. 3, the porous abrasive member 304 includes an open mesh substrate 306, a make coat 314, a plurality of abrasive particles 312, and a size coat 315. The porous polishing member 304 includes a plurality of openings 316 that penetrate the porous polishing member. The opening 316 is formed by the opening 318 of the open mesh base material 306.

  The open mesh substrate can be made of any porous material including, for example, perforated films, nonwovens, or woven or knitted fabrics. In the embodiment shown in FIG. 3, the open mesh substrate 306 is a perforated film. Substrate films may be made from metal, paper, or plastics including molded thermoplastic materials and molded thermoset resin materials. In some embodiments, the open mesh substrate includes stretched sheet material that is perforated or slit. In some embodiments, the open mesh substrate includes fiberglass, nylon, polyester, polypropylene, or aluminum.

  The opening 318 of the open mesh substrate 306 can be generally square, as shown in FIG. In another embodiment, the shape of the opening is, for example, a rectangular shape, a circular shape, an elliptical shape, a triangular shape, a parallelogram shape, a polygonal shape, or other geometric shapes including a combination of these shapes, Also good. The openings 318 of the open mesh substrate 306 can be uniform in size and arrangement, as shown in FIG. In other embodiments, the openings may be any of the random placement, random shape and random dimensions, for example, by using a random opening arrangement pattern, by changing the size or shape of the openings. Depending on the combination, it can be arranged non-uniformly.

  In another aspect, a porous abrasive member may be formed using a screen abrasive having a woven or knitted fabric substrate. The woven substrate typically includes a plurality of generally parallel warp elements extending in a first direction and a plurality of generally parallel weft elements extending in a second direction. A plurality of openings are formed by crossing the weft elements and warp elements of the open mesh base material. By making the second direction perpendicular to the first direction, a square opening can be formed in the woven open mesh base material. In some embodiments, a rhombus pattern is formed by intersecting the first direction and the second direction. The shape of the opening may be other geometric shapes, and examples thereof include a rectangular shape, a circular shape, an elliptical shape, a triangular shape, a parallelogram shape, a polygonal shape, or a combination of these shapes. In some embodiments, the warp and weft elements are woven yarns that are woven together in a one-over-one.

  The warp and weft elements can be combined in any manner known to those skilled in the art including, for example, weaving, stitch bonding, or adhesive bonding. The warp and weft elements may be fibers, long fibers, yarns, woven yarns, or combinations thereof. The warp and weft elements may be made of a variety of materials known to those skilled in the art including, for example, synthetic fibers, natural fibers, glass fibers, and metals. In some embodiments, the warp and weft elements comprise a single fiber of thermoplastic material or metal wire. In some embodiments, the woven open mesh substrate comprises nylon, polyester, or polypropylene.

  Regardless of whether it is a screen abrasive, a perforated coated abrasive, or otherwise, the porous abrasive member may include openings having various opening areas. The “opening area” of the opening of the porous polishing member is the area of the opening when the entire thickness of the porous polishing member is measured (ie, an opening through which a three-dimensional object can pass is formed. The area surrounded by the outer edge of the material. Useful porous abrasive members typically have an average open area of at least about 0.5 square millimeters per opening. In some embodiments, the porous abrasive member has an average open area of at least about 1 square millimeter per opening. In still further embodiments, the porous abrasive member has an average open area of at least about 1.5 square millimeters per opening.

  Whether the porous abrasive member is woven, perforated or otherwise, not only the amount of air that can pass through the porous abrasive member, but also the effective area and performance of the abrasive layer. Includes the total open area to affect. The “total opening area” of the porous polishing member refers to the cumulative opening area of the opening when the entire area formed by the outer edge of the porous polishing member is measured. The porous abrasive member has a total open area of at least about 0.01 square centimeters (ie, 1 percent open area) per square centimeter of the abrasive layer. In some embodiments, the porous abrasive member has a total open area of at least about 0.03 square centimeters per square centimeter of abrasive layer (ie, 3 percent open area). In still further embodiments, the porous abrasive member has a total open area of at least about 0.05 square centimeters (ie, 5 percent open area) per square centimeter of the abrasive layer.

  Typically, the porous abrasive member has a total open area of less than about 0.95 square centimeters per square centimeter of abrasive layer (ie, 95 percent open area). In some embodiments, the porous abrasive member has a total open area that is less than about 0.9 square centimeters per square centimeter of abrasive layer (ie, 90 percent open area). In still further embodiments, the porous abrasive member has a total open area of less than about 0.80 square centimeters per square centimeter of the abrasive layer (ie, 80 percent open area).

  As described above, the porous abrasive member, whether it is a perforated coated abrasive, a coated screen abrasive, a non-woven abrasive, or otherwise, a plurality of abrasive particles, And at least one binder. In some embodiments, the abrasive layer comprises a make coat, a size coat, a supersize coat, or a combination thereof. In some embodiments, the abrasive layer is provided at least in part by curing a slurry coat comprising abrasive particles in a binder precursor. Typically, by coating at least a portion of a substrate (eg, a treated or untreated backing, open mesh, or nonwoven fibrous web) with a make layer precursor that includes a first binder precursor. A makeup layer of the coated abrasive is prepared.

  There may be one or more treatments (eg, backsize, presize, saturant, or subsize) on the substrate. Suitable substrates are widely known in the art of polishing and include, for example, metal foils, paper, fabrics such as knitted fabrics, nonwoven fabrics, or woven fabrics (open scrims and densely woven fabrics). ), Woven mesh (eg, scrim), plastic film (eg, including thermoplastic materials such as polyester, polyethylene, and polypropylene), and combinations thereof. In some embodiments, the substrate does not have a laminated structure.

  The substrate is preferably relatively thin and flexible. For example, in some embodiments, the thickness of the substrate can be less than 1 millimeter, less than 0.5 millimeter, or less than 0.1 millimeter. In some embodiments, the holes, holes, or other porous features that penetrate the thickness of the substrate have a substantially uniform cross-section throughout its length.

  Next, the make layer precursor including the first binder precursor is at least partially embedded (eg, by electrostatic coating or drop coating) to at least partially cure the make layer precursor. The electrostatic coating of abrasive particles typically results in upright oriented abrasive particles. In the context of abrasive articles, the term “uprightly oriented” refers to the longer dimension of the majority of abrasive particles oriented generally perpendicular to the backing (ie, between 60 and 120 degrees). Refers to the placed feature. Other techniques for aligning the abrasive particles upright may also be used.

  Subsequently, a size layer precursor containing a second binder precursor (which may be the same as or different from the first binder precursor) is coated on at least a part of the makeup layer and abrasive particles. Thus, the size layer is prepared by at least partially curing the size layer precursor. In some coated abrasive articles, the supersize is applied to at least a portion of the size layer. If present, the supersize layer typically includes grinding aids and / or clogging materials.

  The binder is typically formed by curing the binder precursor (eg, by thermal means or using electromagnetic radiation or particulate radiation). Useful binder precursors suitable for use in make coats, size coats, supersize coats, and slurry coats are well known in the abrasive arts, for example, free radical polymerizable monomers and / or oligomers. , Epoxy resins, acrylic resins, urethane resins, phenol resins, urea formaldehyde resins, melamine formaldehyde resins, amine plast resins, cyanate resins, or combinations thereof. Useful binder precursors include thermosetting resins and radiation curable resins, which can be cured, for example, by thermal curing and / or exposure to radiation.

  As is well known in the art, catalysts, initiators, and / or curing agents may be used in combination with binder precursors, typically in effective amounts.

  Abrasive particles suitable for coated abrasives include, for example, any known abrasive particles or abrasives commonly used in abrasive articles. Examples of abrasive particles useful for coated abrasives include, for example, molten aluminum oxide, heat treated aluminum oxide, white molten aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, tungsten carbide, Titanium carbide, diamond, cubic boron nitride, garnet, fused alumina zirconia, sol-gel abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, silicates, metal carbonates (e.g., calcium carbonate (e.g., Chalk, calcite, mudstone, travertine, marble, and limestone), magnesium calcium carbonate, sodium carbonate, magnesium carbonate), silica (eg, quartz, glass beads, glass spheres, and glass fibers) silicates (eg, , Talc, clay, (montmorillonite) head , Mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate), metal sulfate (eg calcium sulfate, barium sulfate, sodium sulfate, sodium aluminum sulfate, aluminum sulfate), gypsum, aluminum trihydrate , Graphite, metal oxides (eg, tin oxide, calcium oxide), aluminum oxide, titanium dioxide, and metal sulfites (eg, calcium sulfite), metal particles (eg, tin, lead, copper), thermoplastics (For example, polycarbonate, polyetherimide, polyester, polyethylene, polysulfone, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, acetal polymers, polyvinyl chloride, polyurethanes, nylon Abrasive plastic particles, cross-linked polymers (for example, phenol resins, aminoplast resins, urethane resins, epoxy resins, melamine-formaldehyde, acrylate resins, acrylated isocyanurate resins, urea formaldehyde resins) And plastic abrasive particles molded from isocyanurate resins, acrylated urethane resins, acrylated epoxy resins), and combinations thereof. The abrasive particles may also be agglomerates or composites that include additional components such as, for example, a binder. Criteria used in selecting the abrasive particles used for a particular polishing application typically include polishing life, cutting rate, substrate surface finish, grinding efficiency, and product cost.

  The coated abrasive member further comprises surface modification additives for abrasive particles, coupling agents, plasticizers, fillers, foaming agents, fibers, antistatic agents, reaction initiators, suspensions. Optional additives such as agents, photosensitizers, lubricants, wetting agents, surfactants, pigments, dyes, UV stabilizers, and suspending agents may be included. . The amount of these materials is selected to give the desired properties. The additives can further be incorporated into the binder, applied as a separate coating, retained in the pores of the agglomerates, or a combination of the foregoing.

  If it is not inherently porous (eg, due to the nature of the substrate), the abrasive member may be perforated by, for example, mechanical drilling (eg, stamping), laser drilling, or any other suitable technique. May be. Any pattern of perforations can be used. The perforations may be, for example, circular or oval, straight, arcuate, or somewhat complicated. The porosity of the porous abrasive member must be sufficient to allow particles (eg, chips) to flow from the outer abrasive surface toward the first and second filter media at a rate comparable to the rate at which they occur. I must.

  Examples of commercially available perforated coated abrasive articles suitable for use as porous abrasive members include the trade designation “Norton Multi-Air” from Wesseling, Germany. Materials available from Saint-Gobain Abrasives GmbH, and 3M Company of Saint Paul, Minnesota as transaction designation “CLEAN SANDING DISC” Coated abrasive discs available from

  In some embodiments, the average thickness of the first and / or second nonwoven filter media is at least 0.5, 1, or at least 5 millimeters and up to 10 or 15 millimeters. In other embodiments, the thickness of the first nonwoven filter media may be up to 20 millimeters, or 30 millimeters or more. In some embodiments, the average thickness of the first nonwoven filter media is less than about 20 millimeters.

In some embodiments, the first and / or second nonwoven filter media have a bulk density of 0.04 to 0.5 grams / cubic centimeter (g / cm ³ ). For example, the bulk density of the first filter medium may be 0.75 to 0.4 g / cm ³ , or 1 to 0.3 g / cm ³ .

  In some embodiments, the first filter media is thicker and optionally less dense than the second filter media. In other embodiments, the second filter media is thicker than the first filter media and optionally less dense.

  The first and / or second filter media of the abrasive article may be electrostatically charged. Electrostatic charging enhances the ability of the filter media to remove particulate matter from the fluid stream by increasing the attractive force between the particles and the filter media surface. Non-impact particles that pass near the fibers of the filter media are more easily extracted from the fluid flow, and impact particles adhere more strongly. Passive electrostatic charging is provided by electrets, dielectric materials that exhibit a semi-permanent or permanent charge. Examples of the electret chargeable polymer material include nonpolar polymers such as polytetrafluoroethylene (PTFE) and polypropylene.

  Several methods are used to charge the dielectric material, all of which can be used to charge the filter media of the abrasive article, including corona discharge, heating of the material in the presence of a charged field, and Cooling, contact charging, spraying of charged particles onto the web, and water jetting or impingement of water droplets onto the surface. In addition, the surface charging capability may be enhanced by using mixed materials. Examples of charging methods include U.S. Reissue Patent No. 30,782 (van Turnhout et al.), U.S. Reissue Patent Nos. 31,285 (Van Turnout et al.), 5,496,507 ( Angajdjivand et al., No. 5,472,481 (Jones et al.), No. 4,215,682 (Kubik et al.), No. 5,057,710 (Nishiura) Et al., And 4,592,815 (Nakao) and 5,976,208 (Rousseau et al.).

  Each of the first and / or second nonwoven filter media includes a plurality of fibers.

  In some embodiments, the first and / or second nonwoven filter media have a fiber size less than about 100 micrometers in diameter, optionally less than about 50 micrometers, and sometimes less than about 1 micrometer in diameter. Contains materials.

  The first and / or second nonwoven filter media can be made from a wide variety of organic polymeric materials including mixtures and blends. Suitable filter media include a wide variety of commercially available materials. Polyolefins such as polypropylene, linear low density polyethylene, poly-1-butene, poly (4-methyl-1-pentene), polytetrafluoroethylene, polychlorotrifluoroethylene; or polyvinyl chloride; polystyrene Aromatic polyarenes such as; polycarbonates; polyesters; and mixtures thereof (including blends or copolymers). In some embodiments, the material includes polyolefins that do not have a branched alkyl radical, and copolymers thereof. In further embodiments, the material includes thermoplastic fiber forming materials (eg, polyolefins such as polyethylene, polypropylene, copolymers thereof). Other suitable materials include: thermoplastic polymers such as polylactic acid (PLA); non-thermoplastic fibers such as cellulose, rayon, acrylic, and modified acrylic (halogen-modified acrylic); from Wilmington, Delaware E. I. Polyamide fibers or polyimide fibers such as those available from EI du Pont de Nemours & Co. under the trade designations NOMEX and KEVLAR; and fiber mixtures of different polymers Is mentioned.

  Nonwoven filter media may be formed into a web by conventional nonwoven techniques including, for example, meltblown, spunbond, carding, air laying (dry laying), or wet laying methods. Details regarding blow molded microfiber webs and methods for making them are well known in the art, for example, US Pat. Nos. 6,139,308 (Berrigan et al.) And 5,496,507. (Angadjivand et al.). A typical meltblown molded nonwoven filter medium is, for example, a bimodal blown molding as described in US patent application Ser. No. 11/461136 (Brandner et al.) Filed Jul. 31, 2006. A microfiber member is mentioned.

  If desired, the nonwoven filter media may have a graded density, such as prepared by contacting a thermoformable nonwoven web with a heat can.

  If desired, the fibers or webs may be charged by known methods including, for example, using corona discharge electrodes or high intensity electric fields. The fibers may be charged during fiber formation, before or during formation of the fibers in the filter media web, or after formation of the filter media web. The fibers forming the second filter medium may be charged after being combined with the first nonwoven filter medium. The second nonwoven filter medium may include fibers coated with a polymer binder or adhesive including a pressure sensitive adhesive.

  The porous bonding layer can pass air. The porous bonding layer may include an adhesive layer, a fabric, a sheet material, a molded body, or a combination thereof. The sheet material can include, for example, a loop or hook portion of a two-part mechanical fitting system. The porous bonding layer may include a pressure sensitive adhesive layer with an optional release liner to protect it during processing.

  In some embodiments, the porous bonding layer comprises a nonwoven, woven, or knitted fabric loop material. This loop material can also be used to secure the abrasive article to a backup pad having complementary mating components.

  Suitable materials for the looped porous bonding layer include both woven and non-woven materials. The woven and knitted fabric porous bonding layer material may have loop-forming long fibers or yarns included in the fabric structure so as to form an upright loop that mates with the hook. Good. Non-woven loop-like joint interface materials may have loops formed by entangled fibers. In some nonwoven loop-like joint interface materials, loops are formed by stitching a nonwoven web with woven yarns to form upstanding loops.

  Useful nonwovens suitable for use as a looped porous bonding layer include, for example, airlaids, spunbonds, spunlaces, meltblown assembled webs, and carded laminated webs. It is done. Nonwoven materials can be bonded in various ways known to those skilled in the art, including needle punching, stitch bonding, hydroentanglement, chemical bonding, thermal bonding, and combinations thereof. The woven or non-woven material used may be made from natural fibers (eg, wood fibers or cotton fibers), synthetic fibers (eg, polyester fibers or polypropylene fibers), or a combination of natural and synthetic fibers. it can. In some embodiments, the porous bonding layer comprises nylon, polyester, or polypropylene.

  In some embodiments, a looped porous bonding layer is selected that has an open structure that does not significantly impede air flow therethrough. In some embodiments, the porous bonding layer material is selected based at least in part on the porosity of the material.

  In some embodiments, the porous bonding layer includes a hook material. The material used to form the hook material useful for the abrasive article may be made in one of a wide variety of ways known to those skilled in the art. Some suitable processes for producing hook materials useful for making porous bonding layers include, for example, US Pat. No. 5,058,247 (Thomas et al.), 4th. 894,060 (Nestegard), 5,679,302 (Miller et al.) And 6,579,161 (Chesley et al.). It is done.

  The hook material may be a porous material such as, for example, a polymer network material described in US Patent Application Publication No. 2004/0170801 (Seth et al.). In another embodiment, an opening may be provided in the hook material to allow air to pass. Any method known to those skilled in the art can be used to form the opening in the hook material. For example, the opening may be cut from the sheet of hook material using, for example, a die, laser, or other drilling device known to those skilled in the art. In another embodiment, the hook material may be formed from an opening.

  The porous bonding layer of the abrasive article is fixed to the filter medium in a manner that does not hinder the flow of air from the filter medium. In some embodiments, the porous bonding layer of the abrasive article is secured to the filter media in a manner that does not substantially inhibit the flow of air from the filter media. The amount of air flow from the porous bonding layer can be at least somewhat limited by introducing an adhesive between the porous bonding layer containing the sheet material and the filter media. The degree of restriction can be in a non-continuous format, such as, for example, a separate bond area (eg, spray spray or starved extrusion die) or a separate bond line (eg, hot melt rotating spray or patterned roll coater). It can be minimized by applying an adhesive between the sheet material of the porous bonding layer and the filter medium.

  Representative useful adhesives include both pressure sensitive and non-pressure sensitive adhesives. Pressure sensitive adhesives are usually tacky at room temperature and can be adhered to the surface by being held lightly with a finger at most, while non-pressure sensitive adhesives include solvents, heat, or radiation. Activating adhesive systems are included. Examples of useful adhesives include those based on the general composition of polyacrylates; polyvinyl ethers; diene-containing rubbers such as natural rubber, polyisoprene, and polyisobutylene; polychloroprene; butyl rubber; butadiene-acrylonitrile polymers Thermoplastic elastomers; styrene-isoprene block copolymers, and block copolymers such as styrene-isoprene-styrene block copolymers, ethylene-propylene-diene polymers, and styrene-butadiene polymers; poly (α-olefins); amorphous Polyolefins; silicones; ethylene-containing copolymers such as poly (ethylene-co-vinyl acetate), poly (ethylene-co-ethyl acrylate), and poly (ethylene-co-ethyl methacrylate); Tan like; polyamides; polyesters; epoxies, poly (vinylpyrrolidone) and vinylpyrrolidone polymers; and mixtures of the like. In addition, adhesives contain additives such as tackifiers, plasticizers, fillers, antioxidants, stabilizers, pigments, diffusing particles, curing agents, and solvents. There is also a case.

  The various layers in the abrasive article can be any suitable attachment type, such as, for example, adhesives, pressure sensitive adhesives, hot melt adhesives, spray adhesives, thermal bonding, needle tacking, stitch bonding, and ultrasonic bonding. They may be attached to each other using In some embodiments, a spray bond such as “3M BRAND SUPER 77 ADHESIVE” available from 3M Company of St. Paul, Minnesota, for example. The layers are attached to each other by applying an agent to one side of the porous abrasive. In other embodiments, the hot melt adhesive is applied to one side of the layer using either a hot melt spray gun or an extruder with a comb shim. In a further embodiment, a preformed adhesive mesh is placed between the layers to be joined.

  Optionally, a seal is applied to the peripheral edge of the adhesive article, typically at least most (if not all) of the peripheral edge so that particles that are not retained by the abrasive article are laterally expanded. Outflow may be reduced or prevented. Examples of seals include welds, tapes, latex coatings, caulks, and sealants (eg, latex or silicone).

  The abrasive articles according to the present invention are generally useful for recovering particles during the polishing process, and in some cases can hold large amounts of particles at a high dispensing rate. Abrasive articles are suitable for use with any apparatus suitable for use with such articles. Examples include random orbital grinders, double action grinders, and disk grinders that utilize or do not utilize the vacuum applied to the porous bonding layer and / or second nonwoven filter media of the abrasive article. Can be mentioned.

  While not wishing to be bound by any particular theory, in the case of abrasive articles according to the present invention, a given component (eg, a first nonwoven filter medium) is a second component (eg, a second nonwoven). Multiple filter media may act so that they can be assisted by the filter media), the second component addresses and compensates for the failure condition of the first component, maintains the overall efficiency high, It is believed that the performance can be increased to the extent that it matches the performance of the abrasive used.

  Thus, in some embodiments, at least a portion (eg, a representative perforated region) of an abrasive article according to the present invention (in an unused state) is in the range of 0.2 to 20 millimeters of water (below). Indicates the pressure drop based on the pressure drop measurement test. For example, at least a portion of the abrasive article according to the present invention (when not in use) exhibits a pressure drop according to a pressure drop measurement test ranging from 1 to 15 millimeters of water, or from 4 to 10 millimeters of water.

The pressure drop measurement test is carried out as follows:
The pressure drop across the thickness of the abrasive article is deployed in series to allow air to flow through the cylinders at a face velocity of 5.2 centimeters per second so that the lengths of the cylinders are oriented vertically. It is determined using a filter medium testing apparatus having a pair of cylinders with equal inner diameters. By mounting a pressure transducer on each cylinder, the pressure in the cylinder is measured. Each adjacent end of the upper and lower cylinders is sealed to the abrasive article. The abrasive article to be tested is secured between the cylinders using the outer abrasive surface of the abrasive article that intersects perpendicularly to that direction and faces the air flow to prevent leakage in the lateral direction. The difference in air pressure between the first and second cylinders is recorded as the pressure drop across the abrasive article.

  All patents, patent applications, and publications cited herein are incorporated by reference as if each were individually incorporated in their entirety.

  The advantages and other embodiments of the present invention are further illustrated by the following examples, but the specific materials and amounts listed therein, as well as other conditions and details, unduly limit the present invention. It should not be interpreted as a thing.

  Unless stated otherwise, all parts, percentages, proportions, etc. in the examples and the following specification are by weight.

  The following abbreviations are used throughout the following examples.

Procedure 1: Sealing the end of the filter media The end of the filter media disk 1 (FM1) is traded from DAP Products, Inc., Baltimore, Maryland, with the transaction designation “DAP ALEX (DAP ALEX). A smooth continuous bead made of silicon-acrylic caulk, manufactured as “PLUS”, was sealed by applying it to surround the peripheral edge (adjacent to the periphery) of the disk. The caulking material was pushed into the end of the filter media with a spatula. The caulk was dried for at least 8 hours. FM1 sealed in this way is called FM3.

Procedure 2: Lamination of transfer tape to abrasive and laser drilling Abrasive sheet 1 (AM1) is available from 3M Company under the trade designation “3M 964 13 MIL TRANSFER TAPE” Lamination was performed on a double-sided transfer tape sheet having the same dimensions by the following procedure. The liner on one side of the tape was removed, and the surface of the AM1 sheet opposite to the outer polishing surface was laminated by hand on the adhesive pressure-sensitive adhesive exposed on the tape. Laser drilling was performed on the laminated abrasive according to the pattern 400 shown in FIG. This layered structure cut into a laser drilled 12.7 cm (5 inch) diameter disk is referred to as AM2.

Procedure 3: Joining of filter medium or abrasive material to AT1 A pressure sensitive adhesive marketed by 3M Company under the trade designation “SUPER 77 SPRAY ADHESIVE” is about 15.2 cm ( A 6 inch square AT1 sheet was applied to the non-looped side and dried at 25 degrees Celsius for about 30 seconds. The dry weight of the adhesive was about 12 milligrams / square centimeter (mg / cm ² ). The circular surface of the filter media FM1, FM2, or FM3, or the abrasive material AM5 or AM6 was laminated to the adhesive-coated surface of AT1. Excess AT1 material protruding from the end of the structure was removed by clipping to produce a circular multilayer structure with approximately the same extent.

Procedure 4: Joining of filter medium and AM2 The liner of the transfer tape AM2 was peeled off to expose the adhesive pressure-sensitive adhesive of the tape. A suitable circular filter media disk (FM1 or FM3) was aligned by hand with this adhesive and laminated by hand so that the AM2 layer and the filter media layer were approximately coextensive.

  In some cases, FM1 and FM3 were pre-laminated on the FM2 disk as described below. In this case, the exposed circular surface of FM1 or FM3 (that is, the surface opposite to the surface bonded to FM2) was laminated on AM2.

  When AM2 is joined to a filter medium that has been subjected to FM4 / FM5 needle tacking, the AM2 is joined to the exposed circular surface of FM4 to form a layer having substantially the same extent.

Procedure 5: Joining FM1 or FM3 and FM2 Use a pressure sensitive adhesive commercially available from 3M Company under the trade designation “SUPER 77 SPRAY ADHESIVE” as a circular filter medium FM1 or FM3. And a circular surface of FM2 and dried at 25 degrees Celsius for about 30 seconds. The dry weight of the adhesive was about 12 milligrams / square centimeter (mg / cm ² ). The two adhesive-coated circular surfaces were then aligned and laminated together. The structure was dried to produce a two-layer structure having substantially the same spread.

Procedure 6: Preparation of FM4 FM4 was made from a 90/10 weight ratio blend of FIB1 and FIB2. This blend had a basis weight of about 155 grains / 648 g / m ² (24 square inches) and a thickness of about 12.7 cm (5 inches). Using the trade notation “RANDO WEBBER” available from Rando Machine Corporation in Macedon, New York, an airlaid web forming machine, using conventional conditions, FM4 was formed from the fiber blend.

Step 7: Joining FM4 and FM5 Upon exiting RANDO WEBBER in step 6, FM4 is placed on top of FM5 and these two layers are placed on the STP impianti Spa (Milan, Italy) The transaction notation “AUTOMATEX” available from STP Impianti Spa was adhered to each other by passing it through a needle tacker at a speed of 1.52 m / min. The speed of this needle tacker was 0.0185 m ² / s (185 strokes) / min, and the punch density was 8.4 punch / cm ² , penetrating from above 15 mm. The needle was of type F20 9-37-9K 15 x 20 x 2.5 and was available from Foster Needle, Manitowoc, Wisconsin. The final basis weight of the needle-tucked FM5 / FM6 filter media was about 855 g / mm ² and the thickness was about 5.2 m. The combined nonwoven structure was passed through a convection oven at 129 degrees Celsius for 2 minutes to bond FIB1 together with the entire structure. The finished structure was cooled to 25 degrees Celsius.

  Using the above procedure, various multilayer abrasive filter media disks as shown in Table 1, Table 2, and Table 3 were prepared. Iterative examples (ie duplicates of the same structure) are represented by the letters that follow the numbers (eg, Example 1a, Example 1b, and Example 1c). The duplicate comparative example is represented by a number following the letter (for example, comparative example A1, comparative example A2, and comparative example A3). Various characteristics of some filter media are listed in Table 4.

  For any particular embodiment, components that are adjacent to each other in the table (eg, porous abrasive members, filter media, and porous bonding layers) are adjacent to each other within the actual abrasive article. Yes. Those skilled in the art will appreciate that the processing order in which the layers are combined together to form a multi-layer abrasive disc is often not particularly important if the desired final structure is obtained.

  In addition, if two or more different filter media are used within the structure of a multi-layer abrasive filter media disk, it will be noted that the order in which the filter media are placed with respect to the abrasive may affect the performance of the abrasive article. . In this regard, different filter media may not be compatible within the multilayer structure. This includes situations where a single filter medium with a gradient in its filtration capacity is utilized (eg, it is substantially heterogeneous in the direction of flow of the particles to be filtered).

Test method Polishing test method 1
A 12.7 centimeter (5.0 inch) diameter abrasive disc is weighed and then obtained from 3M Company under the trade designation “3M HOOKIT BACKUP PAD, # 20206” A 40 hole diameter 12.7 cm (5.0 inch) x 0.95 cm (3/8 inch) thick foam backing pad was bonded. This backing pad and disk assembly was then obtained from Dynabrade Corp., Clarence, NY, a dual action orbital polisher for medium finishing of 12.7 cm (5 inches) in diameter. And attached to model 21033. The polished surface of this disk was obtained from White Bear Boat Works, White Bear Lake, Minnesota, pre-weighed 46 cm x 76 cm (18 inches x 30 inches) Manually contacted with a gel-coated fiberglass reinforced plastic panel. The polisher was operated for two cycles at 75 seconds each cycle with an airline pressure of 620 kPa (90 psi) and a downward force of 44 N (10 weight pounds). An angle of 0 degrees with respect to the workpiece surface was used. Pass across the panel surface for each cycle consisting of 24 passes across the same location at a tool speed of 17 cm per second (6.7 inches per second) with a total length of 12.8 meters (504 inches). Thus, a test panel having a uniform polished surface is obtained. After the first polishing cycle, the test panel was cleaned by blowing compressed air over the entire top surface of the polished panel to remove visible dust. The disc was removed from the backing pad and both the panel and disc were weighed. The abrasive was reattached to the backing pad and the 75 second polishing cycle was repeated using the same test panel. The test panel was again cleaned by blowing compressed air over the entire top surface of the polished panel to remove visible dust. The abrasive disc was removed from the backing pad and both the panel and abrasive disc were weighed. The reported data is after the second polishing cycle and the accumulated polishing time is 150 seconds.

The following measurements were obtained for each sample tested in this manner and were reported as the average of two test samples for each of the examples in Tables 1 and 2 above:
“Cutting amount”: weight (grams) removed from the plastic panel;
“Holding amount”: weight (g) of particles collected in the sample disc; and “DE%”: the ratio of holding amount / cutting amount multiplied by 100.

Polishing test method 2
A 12.7 cm (5.0 inch) abrasive filter media disk was weighed and bonded to the backing pad, and the disc / pad assembly was then attached to the orbital polisher as described in Polishing Test Method 1. The polished surface of the disk was obtained from White Bear Boat Works, White Bear Lake, Minnesota, pre-weighed 45.7 cm x 76.2 cm (18 inches x 30 inch) gel-coated fiberglass reinforced plastic panels were manually contacted. The polisher was operated for 6 cycles at 25 seconds each cycle with an airline pressure of 620 kPa (90 psi). An angle of 0 degrees with respect to the workpiece surface was used. After the first three cycles, the test panel was cleaned by blowing compressed air across the top surface of the polished panel to remove visible dust. The disc was removed from the backing pad and both the panel and disc were weighed. The abrasive was reattached to the backing pad and the last three polishing cycles were performed using the same test panel. The test panel was again cleaned by blowing compressed air over the entire top surface of the polished panel to remove visible dust. The abrasive disc was removed from the backing pad and both the panel and abrasive disc were weighed. The data reported was after the 6th polishing cycle and the cumulative polishing time was 150 seconds.

The following measurements were obtained for each sample tested in this manner and were reported as the average of two test samples for each of the examples in Tables 1 and 2 above:
“Cutting amount”: weight (grams) removed from the plastic panel;
“Holding amount”: weight (g) of particles collected in the sample disc; and “DE%”: the ratio of holding amount / cutting amount multiplied by 100.

Surface finish measurement test method The resulting surface roughness of the polished test panels is trade name “PERTHOMETER MODEL M4P-130589” from Mahr Corporation of Cincinnati, Ohio Determined using available surface finish test equipment. The surface finish value was measured at three polishing sites on the test panel every time the 150 second polishing test was completed. Rz (also known as Rtm) is the average of the maximum peak-to-valley values and was recorded for each measurement.

Improved Pressure Drop Measurement Test The pressure drop measurement test herein was performed at a flow rate of 32 liters per second using a filtration test apparatus with a pair of cylinders with an inner diameter of 11.4 cm (4.5 inches). The pressure transducer was obtained from MKS Instruments, Wilmington, Mass., As trade designation “MKS BARATRON PRESSURE TRANSDUCER, 398HD-00010SP12” (1.33 kPa (10 torr) limit).

  Polishing test 1 was used as a polishing procedure corresponding to the data created in Table 1. Polishing test 2 was used as a polishing procedure corresponding to the data created in Table 2.

  Improved pressure drop test measurements were not performed in all examples. Improved pressure drop tests for the specific examples reported in Tables 1 and 2 are reported in Table 3 along with data for additional comparative examples.

  Improved pressure drop test measurements were made on abrasive articles prior to any polishing by Polishing Test Method 1 or Polishing Test Method 2, except those shown in Table 3.

  Examples 1b, 2b, 3b, 4b and Comparative Example A2 were all performed using the same gel-coated fiberglass reinforced plastic panel. Examples 6, 7 and Comparative Example A3 were all performed using the same gel-coated fiberglass reinforced plastic panel but a panel different from the above Examples and Comparative Examples. Example 5 and Comparative Example A4 were performed on another panel. A wide variety of panels can lead to various cut amount measurements.

^＊ （上記）表３中の実施例１ｂ及び３ｂは、研磨試験法２の終了後に測定した。

^* (Above) Examples 1b and 3b in Table 3 were measured after polishing test 2 was completed.

  While various modifications and alternatives of the present invention may be made by those skilled in the art without departing from the scope and spirit of the invention, the invention is not limited to the specific embodiments described herein. It should be understood that this is not a limitation.

Claims (2)

An abrasive article,
A porous abrasive member comprising an abrasive layer secured adjacent to a first surface of a substrate, wherein the abrasive layer is secured to the first surface of the substrate by at least one binder. A plurality of abrasive particles, wherein the abrasive layer has an outer polishing surface, the substrate has a second surface opposite to the first surface of the substrate, A porous abrasive member extending from the outer abrasive surface to the second surface of the substrate and comprising a perforated coated abrasive or a coated screen abrasive ;
A first nonwoven filter medium having a first surface and a second surface opposite to the first surface, wherein the first surface of the first nonwoven filter medium is adjacent to the second surface of the substrate. A first nonwoven filter medium, wherein the first nonwoven filter medium includes a plurality of fibers;
A second nonwoven filter medium having a first surface and a second surface opposite to the first surface, wherein the first surface of the second nonwoven filter medium is adjacent to the second surface of the first nonwoven filter medium. A second non-woven filter medium, wherein the second non-woven filter medium includes a plurality of fibers.
The particles flow through the plurality of openings and the first nonwoven filter medium from the outer polishing surface toward the second nonwoven filter medium, and in an unused state, at least a part of the abrasive article is water An abrasive article exhibiting a pressure drop according to a pressure drop measurement test ranging from 0.2 to 20 milliliters. A method for producing an abrasive article, comprising:
Providing a porous abrasive member comprising an abrasive layer affixed adjacent to a first surface of a substrate, wherein the abrasive layer is at least one binder and the first surface of the substrate. A plurality of abrasive particles fixed to the substrate, the abrasive layer has an outer polishing surface, and the base material has a second surface opposite to the first surface of the base material. A plurality of openings extending from the outer polishing surface to the second surface of the substrate, wherein the porous polishing member is formed by a perforated coated abrasive or a coated screen abrasive. Including a process,
A step of providing a first nonwoven filter medium, wherein the first nonwoven filter medium has a first surface and a second surface opposite to the first surface, and the first nonwoven filter medium includes a plurality of fibers. The first surface of the first non-woven filter medium is adjacent to the second surface of the substrate;
A step of providing a second nonwoven filter medium, wherein the second nonwoven filter medium has a first surface and a second surface opposite to the first surface, and the second nonwoven filter medium includes a plurality of second nonwoven filter media. Including a fiber, wherein the first surface of the second nonwoven filter medium is adjacent to the second surface of the first nonwoven filter medium;
Fixing the first nonwoven filter medium to the second surface of the substrate;
Fixing the second non-woven filter medium to the first non-woven filter medium,
Through the plurality of openings and the first nonwoven filter medium, the particles flow from the outer polishing surface toward the second nonwoven filter medium, and in an unused state, at least a part of the abrasive article is Manufacturing method showing a pressure drop according to a pressure drop measurement test in the range of 0.2 to 20 ml of water.

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