Abrasive products comprising impregnated woven fabric and abrasive particles

Abstract

An abrasive product comprising an impregnated woven fabric comprising: a) A first layer of first uncrimped weft multifilaments (301-308) b) a second layer of second uncrimped weft multifilaments (309-316); wherein for each of the first uncrimped weft multifilaments (301-308) there is one corresponding second uncrimped weft multifilament (309-316), and vice versa, to form successive multifilament pairs (301/309, 302/310, 303/311, 304/312, 305/313, 306/314, 307/315, 308/316) of first and second uncrimped weft multifilaments; c) crimped warp filaments (41-44) having four different weave types d-c4, but each weave type consisting of entwining around first uncrimped weft multifilaments; passing between first and second uncrimped weft multifilaments; entwining around second uncrimped weft multifilaments; and passing again between first and second uncrimped weft multifilaments; d) uncrimped warp filaments (4) passing between first (301-308) and second (309-316) uncrimped weft multifilaments of all multifilament pairs (301/309, 302/310, 303/311, 304/312, 305/313, 306/314, 307/315, 308/316). The abrasive product furthermore comprises either a first particulate abrasive material (9) embedded into the first topmost surface (8) of the first top layer (7), or a prefabricated abrasive sheet (101) comprising a matrix material, a first top sheet surface (111) and first abrasive particles (91) embedded into the first top sheet surface (111).

1 . An abrasive product comprising
 i) a woven fabric which is impregnated with an impregnation ( 6 ) comprising or consisting of a thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixture thereof; the fabric comprising:
 a) A first layer (A) of first uncrimped weft multifilaments ( 301 - 308 ) running essentially in parallel to each other and being spaced apart from each other by a distance D; 
 b) a second layer (B) of second uncrimped weft multifilaments ( 309 - 316 ) running essentially in parallel to each other and being spaced apart from each other by said distance D; 
  wherein for each of the first uncrimped weft multifilaments ( 301 - 308 ) there is one corresponding second uncrimped weft multifilament ( 309 - 316 ), and vice versa, to form successive multifilament pairs ( 301 / 309 ,  302 / 310 ,  303 / 311 ,  304 / 312 ,  305 / 313 ,  306 / 314 ,  307 / 315 ,  308 / 316 ), each such successive multifilament pair being designable with a unique and ascending integer index N; 
 c) crimped warp filaments ( 41 - 44 ) having one of the following weave types c1-c4: 
  c1-entwine around first uncrimped weft multifilaments ( 302 ,  306 ) of all multifilament pairs ( 302 / 310 ,  306 / 314 ) with indexes N fulfilling (N mod  4 )=0, such indexes N being designated as N A ; pass between first ( 303 ,  307 ) and second ( 311 ,  315 ) uncrimped weft multifilaments of all multifilament pairs ( 303 / 311 ,  307 / 315 ) with indexes N fulfilling (N mod  4 )=1, such indexes N being designated as N B ; entwine around second uncrimped weft multifilaments ( 312 ,  316 ) of all multifilament pairs ( 304 / 312 ,  308 / 316 ) with indexes N fulfilling (N mod  4 )=2, such indexes N being designated as N C ; and pass between first ( 301 ,  305 ) and second ( 309 ,  313 ) uncrimped weft multifilaments of all multifilament pairs ( 301 / 309 ,  305 / 313 ) with indexes N fulfilling (N mod  4 )=3, such indexes N being designated as N D ; or 
  c2-entwine around second uncrimped weft multifilaments ( 310 ,  314 ) of all multifilament pairs with said indexes N A ; pass between first ( 303 ,  307 ) and second ( 311 ,  315 ) uncrimped weft multifilaments of all multifilament pairs ( 303 / 311 ,  307 / 315 ) with said indexes N B ; entwine around first uncrimped weft multifilaments ( 304 ,  308 ) of all multifilament pairs ( 304 / 312 ,  308 / 316 ) with said indexes N C ; and pass between first and second uncrimped weft multifilaments of all multifilament pairs ( 301 / 309 ,  305 / 313 ) with said indexes N D ; or 
  c3-pass between first ( 302 ,  306 ) and second ( 310 ,  314 ) uncrimped weft multifilaments of all multifilament pairs ( 302 / 310 ,  306 / 314 ) with said index N A ; entwine around first uncrimped weft multifilaments ( 303 ,  307 ) of all multifilament pairs ( 303 / 311 ,  307 / 315 ) with said indexes N B ; pass between first ( 304 ,  308 ) and second ( 312 ,  316 ) uncrimped weft multifilaments ( 304 / 312 ,  308 / 316 ) of all multifilament pairs with said indexes N C ; and entwine around second uncrimped weft multifilaments ( 309 ,  313 ) of all multifilament pairs ( 301 / 309 ,  305 / 313 ) with said indexes N D ; or 
  c4-pass between first ( 302 ,  306 ) and second ( 310 ,  314 ) uncrimped weft multifilaments of all multifilament pairs ( 302 / 310 ,  306 / 314 ) with said indexes N A ; entwine around second uncrimped weft multifilaments ( 311 ,  315 ) of all multifilament pairs ( 303 / 311 ,  307 / 315 ) with said indexes N B ; pass between first ( 304 ,  308 ) and second ( 312 ,  316 ) uncrimped weft multifilaments of all multifilament pairs ( 304 / 312 ,  308 / 316 ) with said indexes N C ; and entwine around first uncrimped weft multifilaments ( 301 ,  305 ) of all multifilament pairs ( 301 / 309 ,  305 / 313 ) with said indexes N D ; 
 d) uncrimped warp filaments ( 1 ) passing between first ( 301 - 308 ) and second ( 309 - 316 ) uncrimped weft multifilaments of all multifilament pairs ( 301  / 309 ,  302 / 310 ,  303 / 311 ,  304 / 312 ,  305 / 313 ,  306 / 314 ,  307 / 315 ,  308 / 316 ); and 
 e) optionally, crimped antistatic warp filaments having one of the weave types c1, c2, c3 or c4 defined above; 
  provided that crimped warp filaments ( 41 - 44 ) of all four above defined weave types c1, c2, c3 and c4 are present; 
  wherein the fabric does not comprise any other crimped warp filaments, besides said crimped warp filaments ( 41 - 44 ) and said optional crimped s antistatic warp filaments; and 
  wherein (N mod  4 ) designates the remainder obtained by Euclidean integer division of N by 4; 
   and either:    iia) immediately adjoining to one side of the impregnated fabric a first top layer ( 7 ) with a first topmost surface ( 8 ) comprising or consisting of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixture thereof as in the impregnation ( 6 ) but being devoid of fabric, and    iiia) a first particulate abrasive material ( 9 ) embedded into the first topmost surface ( 8 ) of the first top layer ( 7 ); or    iib) optionally, immediately adjoining to one side of the impregnated fabric, a first cover layer ( 71 ) comprising or consisting of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixture thereof as in the impregnation ( 6 ) but being devoid of fabric;    iiib) adjoining to said one side of the impregnated fabric, or, if the first cover layer ( 71 ) is present, to said first cover layer ( 71 ), a first prefabricated abrasive sheet ( 101 ) comprising a matrix material, a first top sheet surface ( 111 ) and first abrasive particles ( 91 ) embedded into the first top sheet surface ( 111 ), wherein said matrix material is different from the impregnation ( 6 ).   
     
     
         2 . The abrasive product of  claim 1 , wherein each uncrimped warp filament ( 1 ) is separated in weft direction from the next uncrimped warp filament ( 1 ) by an even number of crimped warp filaments ( 41 - 44 ), said even number being at least 2. 
     
     
         3 . The abrasive product of  claim 1 , wherein each uncrimped warp filament ( 1 ) is sandwiched in weft direction by two immediately adjacent crimped warp filaments ( 42 , 43 ). 
     
     
         4 . The abrasive product of  claim 1 , wherein the crimped warp filaments of weave types c1 ( 41 ) and c2 ( 42 ) defined in  claim 1  are always present pairwise and immediately adjacent to each other in weft direction, and the crimped warp filaments of weave types c3 ( 43 ) and c4 ( 44 ) defined in  claim 1  are always present pairwise and immediately adjacent to each other in weft direction. 
     
     
         5 . The abrasive product of  claim 1 , wherein the numerical ratio of crimped warp filaments c) ( 41 - 44 ) to uncrimped warp filaments d) ( 1 ) is in the range of 4:1 to 12:1. 
     
     
         6 . The abrasive product of  claim 1 , wherein the crimped warp filaments c) ( 41 ,  42 ,  43 ,  44 ) and the uncrimped warp filaments d) ( 4 ) are arranged in repetitive units in weft direction, in which repetitive units the order in which the uncrimped warp filaments d) ( 1 ) and the crimped warp filaments of above weave types c1 ( 41 ), c2 ( 42 ), c3 ( 43 ) and c4 ( 44 ) are arranged in weft direction is always the same. 
     
     
         7 . The abrasive product of  claim 1 , comprising the crimped antistatic warp filaments e). 
     
     
         8 . The abrasive product of  claim 1 , consisting of first uncrimped weft multifilaments a) ( 301 - 308 ), second uncrimped weft multifilaments b) ( 309 - 316 ), crimped warp filaments c) ( 41 - 44 ), uncrimped warp filaments d) ( 1 ) and optional crimped antistatic warp filaments e). 
     
     
         9 . The abrasive product of  claim 1 , comprising iia) and iiia) defined in  claim 1 . 
     
     
         10 . The abrasive product of  claim 9 , which is an endless abrasive belt, and wherein the warp direction of the fabric is in the travel direction of the belt. 
     
     
         11 . The abrasive product of  claim 9 , furthermore comprising:
 iv) immediately adjoining to the other side of the impregnated fabric a second top layer with a second topmost surface and being made of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixture thereof as in the impregnation ( 6 ) in the fabric but being devoid of fabric; and   v) a second particulate abrasive material embedded into the second topmost surface of the second top layer.   
     
     
         12 . The abrasive product of  claim 1 , comprising iib) and iiib) defined in  claim 1 . 
     
     
         13 . The abrasive product of  claim 12 , furthermore comprising:
 iv) optionally, immediately adjoining to the other side of the impregnated fabric, a second cover layer ( 72 ) comprising or consisting of the same thermoplastic, thermoplastic elastomer, thermoset, elastomer or mixture thereof as in the impregnation ( 6 ) but being devoid of fabric;   v) adjoining to said other side of the impregnated fabric, or, if the second cover layer ( 72 ) is present, to said second cover layer ( 72 ), a second prefabricated abrasive sheet ( 102 ) comprising a matrix material, a second top sheet surface ( 112 ) and second abrasive particles ( 92 ) embedded into the second top sheet surface ( 112 ), wherein said matrix material is different from the impregnation ( 6 ).   
     
     
         14 . The abrasive product of  claim 12 , which is an abrasive pad or abrasive disk. 
     
     
         15 . The abrasive product of  claim 1 , wherein the impregnation ( 6 ) is of a thermoplastic or thermoplastic elastomer, in particular a TPU.