Abrasive article and method of using the same

Abstract

An abrasive article having first and second major surfaces includes a lofty open nonwoven fiber web comprising entangled fibers. The fiber web includes a densified outer layer comprising a portion of nonwoven fiber web proximate to the first major surface. At least a portion the entangled fibers in the densified outer layer are melt-bonded to one another. An abrasive material is coated on the densified outer layer. The abrasive material includes abrasive particles having a median particle diameter D50 in the range of 1 to 15 microns retained in a binder material. The abrasive article has a Stiffness Test force of 0.1 to 5.0 pounds (0.45 to 2.27 kg) or less. The abrasive article can be used to abrade a workpiece.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a single, non-laminated layer of a nonwoven fiber web, the nonwoven fiber web comprising entangled fibers;   an abrasive material coated on the non-laminated layer of nonwoven fiber web; and   wherein the abrasive article has a void volume of at least 75%.   
     
     
         2 . The abrasive article of  claim 1 , wherein the abrasive article has a void volume of at least 95%. 
     
     
         3 . The abrasive article of  claim 1 , wherein the non-laminated layer of nonwoven fiber web has a first surface opposed to a second surface, and wherein the non-laminated layer of nonwoven fiber web has a densified region proximate one or both of the first and second surfaces. 
     
     
         4 . The abrasive article of  claim 3 , wherein the densified region is formed by a mechanical operation. 
     
     
         5 . The abrasive article of  claim 3 , wherein the densified region is formed by melt-bonding at least a portion of the entangled fibers to one another. 
     
     
         6 . The abrasive article of  claim 1 , wherein the abrasive material comprises abrasive particles retained in a binder material. 
     
     
         7 . The abrasive article of  claim 6 , wherein the abrasive material is coated on a first surface of the non-laminated layer of nonwoven fiber web, and wherein a second surface of the non-laminated layer of nonwoven fiber web is substantially free of abrasive particles. 
     
     
         8 . The abrasive article of  claim 6 , wherein the abrasive particles have a median particle diameter in the range of 1 to 15 microns. 
     
     
         9 . The abrasive article of  claim 8 , wherein the abrasive particles have a median particle diameter in the range of 2-12 microns. 
     
     
         10 . The abrasive article of  claim 9 , wherein the abrasive particles have a median particle diameter in the range of 4-10 microns. 
     
     
         11 . A method of manufacturing a non-laminated abrasive article, the method comprising:
 densifying a region of a nonwoven fiber web;   applying an abrasive precursor material to the densified nonwoven fiber web;   curing the abrasive precursor material; and   wherein the resulting abrasive article has a Stiffness Test Force between about 1.0 to about 5.0 pounds.   
     
     
         12 . The method of  claim 11 , wherein the abrasive article has a void volume of at least 75%. 
     
     
         13 . The method of  claim 11 , wherein densifying comprises either a mechanical densifying step or a heating densifying step. 
     
     
         14 . The method of  claim 11 , and further comprising applying a pre-bond resin to the nonwoven fiber web. 
     
     
         15 . The method of  claim 11 , wherein the abrasive precursor material is applied as a continuous layer to the densified nonwoven fiber web. 
     
     
         16 . The method of  claim 11 , and further comprising applying the nonwoven fiber web to a backing. 
     
     
         17 . A method of abrading a surface, the method comprising:
 frictionally contacting an abrasive article to a workpiece;   moving at least one of the workpiece and the abrasive article relative to the other; and   wherein the abrasive article comprises a stiff non-woven fiber web with a plurality of abrasive particles, and wherein the stiff non-woven abrasive article has a Stiffness Test force of 0.1 to 5.0 pounds or less.   
     
     
         18 . The method of  claim 17 , wherein the non-woven fiber web comprises at least some melt-bondable fibers. 
     
     
         19 . The method of  claim 17 , wherein the non-woven fiber web comprises a densified region, and wherein the abrasive particles are applied to the densified region. 
     
     
         20 . The method of  claim 17 , wherein the abrasive article is operated in combination with a power tool.