Discontinuous Abrasive Particle Releasing Surfaces

Abstract

Discontinuous abrasive particle releasing surfaces are disclosed that may be employed in low speed wet grinding, sanding, and polishing operations. The discontinuous abrasive surfaces of the present invention may consist of abrasive containing protrusions attached to rigid or flexible surfaces or alternatively may be comprised of closed cell foam compositions impregnated with abrasive materials such as aluminum oxide. The voids present in the discontinuous abrasive surfaces of the present invention serve to hold water and remove debris. The resulting discontinuous abrasive particle releasing surfaces are long lasting and may be made low in cost.

1 . An abrasive article for wet application comprising: 
 a backing having at least one major surface;    a material matrix attached to said major surface, forming a discontinuous surface topography on said major surface; and    a plurality of abrasive particles embedded within said material matrix, wherein said material matrix is wearable by said abrasive particles.    
   
   
       2 . The abrasive article for wet application of  claim 1  wherein said plurality of abrasive particles is dispersed in a substantially uniform manner throughout said material matrix.  
   
   
       3 . The abrasive article for wet application of  claim 1  wherein said discontinuous surface topography is comprised of a plurality of protrusions.  
   
   
       4 . The abrasive article for wet application of  claim 1  wherein said discontinuous surface topography is comprised of a plurality of cavities.  
   
   
       5 . The abrasive article for wet application of  claim 1  wherein said material matrix wearing away causes said plurality of abrasive particles to release in free form, whereby said plurality of abrasive particles released in free form facilitate in wearing down said material matrix.  
   
   
       6 . The abrasive article for wet application of  claim 5  wherein said plurality of abrasive particles released in free form, wear away said material matrix, forming a wet abrasive paste, whereby said wet abrasive paste keeps said plurality of abrasive particles active on the working surface.  
   
   
       7 . The abrasive article for wet application of  claim 1  wherein said backing is rigid.  
   
   
       8 . The abrasive article for wet application of  claim 1  wherein said backing is flexible.  
   
   
       9 . The abrasive article for wet application of  claim 8  wherein said flexible backing is fabric.  
   
   
       10 . The abrasive article for wet application of  claim 8  wherein said flexible backing is a glove.  
   
   
       11 . The abrasive article of wet application of  claim 1  wherein said plurality of abrasive particles comprise of material selected from the group consisting of aluminum oxide, silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, ground glass, quartz, and combinations thereof.  
   
   
       12 . An abrasive article for wet application comprising: 
 a rigid polymeric closed cell foam substrate having at least one major surface, said at least one major surface having a discontinuous surface topography;    a plurality of abrasive particles dispersed within said rigid polymeric closed cell foam, wherein said rigid polymeric closed cell foam is wearable at said major surface by said plurality of abrasive particles.    
   
   
       13 . The abrasive article for wet application of  claim 12  further comprising means for softening said major surface upon exposure to water, whereby a cushion is formed for said plurality of abrasive particles.  
   
   
       14 . The abrasive article for wet application of  claim 12  wherein said rigid polymeric closed cell foam contains a hydrophilic additive, whereby said hydrophilic additive facilitates in softening of said major surface upon exposure to water.  
   
   
       15 . The abrasive article for wet application of  claim 14  wherein said hydrophilic additive is chemically bound to polymers within said rigid polymeric closed cell foam.  
   
   
       16 . The abrasive article for wet application of  claim 12  wherein said rigid polymeric closed cell foam comprises of a condensation polymer.  
   
   
       17 . The abrasive article of  claim 16 , wherein said condensation polymer has a reduced molecular weight formed by polymerization using an excess of at least one reactant, whereby said reduced molecular weight condensation polymer facilitates in softening of said major surface upon exposure to water.  
   
   
       18 . The abrasive article of  claim 17  wherein said excess reactant is hydrophilic.  
   
   
       19 . The abrasive article for wet application of  claim 12  wherein said major surface wears away, revealing a renewed surface having a discontinuous surface topography.  
   
   
       20 . The abrasive article for wet application of  claim 19  wherein said rigid polymeric closed cell foam contains a water soluble material, whereby said water soluble material facilitates in wearing away of said major surface upon exposure to water.  
   
   
       21 . The abrasive article for wet application of  claim 19  wherein said rigid polymeric closed cell foam wearing away causes said plurality of abrasive particles to release in free form, whereby said plurality of abrasive particles released in free form facilitates in wearing away of said major surface.  
   
   
       22 . The abrasive article for wet application of  claim 21  wherein said plurality of abrasive particles released in free form, wear away said rigid polymeric closed cell foam, forming a wet abrasive paste, whereby said wet abrasive paste keeps said plurality of abrasive particles active on the working surface.  
   
   
       23 . The abrasive article for wet application of  claim 12  wherein said plurality of abrasive particles when released in free form create additional voids in said major surface and said plurality of abrasive particles, after release, abrade said major surface, whereby said plurality of abrasive particles released in free form facilitate in wearing away of said major surface.  
   
   
       24 . The abrasive article for wet application of  claim 12  wherein said discontinuous surface topography is comprised of a plurality of voids.  
   
   
       25 . The abrasive article for wet application of  claim 12  wherein said plurality of abrasive particles are dispersed in a substantially uniform manner throughout said rigid polymeric closed cell foam.  
   
   
       26 . The abrasive article for wet application of  claim 12  wherein said rigid polymeric closed cell foam forms the article in its entirety, whereby no separate backing or handle is required.  
   
   
       27 . The abrasive article of wet application of  claim 12  wherein said plurality of abrasive particles comprise of material selected from the group consisting of aluminum oxide, silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, ground glass, quartz, and combinations thereof.  
   
   
       28 . An abrasive article for wet application comprising: 
 a matrix material with a plurality of hollow microspheres embedded throughout having at least one major surface, said at least one major surface having discontinuous surface topography; and    a plurality of abrasive particles dispersed within said matrix material, wherein said matrix material is wearable at said major surface by said plurality of abrasive particles.    
   
   
       29 . The abrasive article for wet application of  claim 28  wherein further comprising means for softening said major surface upon exposure to water, whereby forming a cushion for said plurality of abrasive particles.  
   
   
       30 . The abrasive article for wet application of  claim 28  wherein said plurality of hollow microspheres are comprised of one or more polymers.  
   
   
       31 . The abrasive article of wet application of  claim 28  wherein said plurality of abrasive particles comprise of material selected from the group consisting of aluminum oxide, silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, ground glass, quartz, and combinations thereof.  
   
   
       32 . A method of abrading an object comprising the steps of: 
 wetting said object;    sliding a major surface of an abrasive article over said object, wherein said abrasive article is comprised of a material matrix with a plurality of abrasive particles dispersed throughout and said major surface has a discontinuous surface topography;    softening said major surface upon exposure to water;    wearing away of said abrasive article at said major surface; and    releasing said plurality of abrasive particles in free form.    
   
   
       33 . The method of abrading an object as defined in  claim 32  further comprising the step of embedding said plurality of abrasive particles released in free form into the softened major surface.  
   
   
       34 . The method of abrading an object as defined in  claim 32  further comprising the step of producing a renewed surface also having a discontinuous surface topology  
   
   
       35 . The method of abrading an object as defined in  claim 32  further comprising the step of exposing and releasing deeper plurality of abrasive particles when said abrasive article wears away at said major surface.  
   
   
       36 . The method of abrading an object as defined in  claim 32  further comprising the step of abrading said major surface by said plurality of abrasive particles released in free form.