Nonwoven abrasive article containing elastomer bound agglomerates of shaped abrasive grain

Abstract

A nonwoven abrasive article formed from a nonwoven web and agglomerates comprising formed ceramic abrasive particles bound together by a first flexible binder, and a second binder binding the agglomerates to the nonwoven fiber web.

1 . A nonwoven abrasive article comprising:
 a nonwoven web;   agglomerates comprising formed ceramic abrasive particles bound together by a first flexible binder; and   a second binder binding the agglomerates to the nonwoven fiber web.   
     
     
         2 . The nonwoven abrasive article of  claim 1  wherein the formed ceramic particles comprise shaped ceramic abrasive particles comprising triangular plates. 
     
     
         3 . The nonwoven abrasive article of  claim 1  wherein the first flexible binder comprises a polyurethane and the second binder comprises a polyurethane. 
     
     
         4 . The nonwoven abrasive article of  claim 1  wherein the first flexible binder comprises a polyurethane and the second binder comprises a phenolic. 
     
     
         5 . The nonwoven abrasive article of  claim 1  wherein a modulus of elasticity of the first flexible binder is less than 28,000 psi. 
     
     
         6 . The nonwoven abrasive article of  claim 1  wherein a modulus of elasticity of the first flexible binder is less than 23,000 psi. 
     
     
         7 . The nonwoven abrasive article of  claim 1  wherein the agglomerates comprise filler particles having an average particles size less than that of the formed ceramic abrasive particles and the filler particles comprise from 5% to 40% by weight of the total particles in the agglomerates. 
     
     
         8 . The nonwoven abrasive article of  claim 1  where the agglomerates have a size comprising a maximum diameter, if generally spherical, or a maximum side edge length if non-spherical from 1.8 to 3 mm. 
     
     
         9 . The nonwoven abrasive article of  claim 1  wherein a ratio of the formed ceramic abrasive particle size divided by the agglomerate size is 0.0033 to 0.5. 
     
     
         10 . The nonwoven abrasive article of  claim 1  wherein the agglomerates comprise filler particles and wherein the formed ceramic abrasive particle content is from 75 wt. % to 96 wt. %, the first flexible binder content is from 4 wt. % to 10 wt. %, and the filler particle content is from 10 wt. % to 35 wt. %. 
     
     
         11 . The nonwoven abrasive article of  claim 1  comprising either a convolute abrasive wheel or a unitized abrasive wheel.