# Patent

## Title
Self-contained fibrous buffing article

## Abstract

A self-contained fibrous buffing article comprising at least one layer of a fibrous nonwoven fabric comprising lyocell fiber and having a hardened adherent coating comprising a crosslinked binder, abrasive particles, and a lubricant.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage filing under 35 U.S.C. 371 of PCT/US2011/062997, filed Dec. 2, 2011, which claims priority to US Provisional Patent Application No. 61/422740, filed Dec. 14, 2010, the disclosures of which are incorporated by reference in their entirety herein


BACKGROUND
Buffing wheels or buffs are generally formed from layers of a fibrous material which are stacked or fastened together. Fastening methods include, for example, compression, sewing, stapling, adhesive bonding, plastic or metal clinch rings, and combinations thereof. The buffing wheel is typically attached to a shaft and supported for rotation. Buffs have long been used to finish items such as machined parts, stamped parts, and cast articles which often have surfaces which must be modified, generally for aesthetic purposes. Buffing is a finishing process which is typically accomplished after more rigorous stock removal treatment of the surface. Buffs are typically rotated to obtain working surface speeds of from 1000 m/min to 2500 m/min.
Buffs are frequently categorized as either “cut” buffs or “color” buffs. A cut buff is more aggressive and is typically employed with a coarser buffing compound, a medium to high pressure between the buff and the workpiece, and the workpiece is advanced against the direction of rotation of the buff. This results in the refinement of scratches on the workpiece and yields a uniform matte finish. A color buff is typically employed with a finer buffing compound, a medium to low pressure between the buff and the workpiece, and the workpiece is advanced in the direction of rotation of the buff. The color buff application results in a further refinement of scratches in the surface of the workpiece and yields a reflective, mirror-like finish.
SUMMARY OF THE INVENTION
Buffs are most often employed to refine surfaces by a three-body abrasion mechanism. Driven buffs transmit energy to a workpiece, but the abrading action is provided by an abrasive composition ‘buffing compound” that is peripherally applied, but not bound, to the buff's surface. Unbonded buffing compounds situated between the workpiece and the buff's surface refines the workpiece surface resulting in fewer and smaller scratches being imparted to the workpiece surface as the buffing continues. While such three-body systems produce the required finishes, the buffing compound must be frequently applied to achieve a consistent finish, can be undesirably transferred onto adjacent surfaces, and leaves a residue on the workpiece surface which then must be removed. Attempts to resolve these deficiencies by employing a two-body abrading system, wherein the abrasive composition is hardened to the working surfaces of the buff or pre-impregnated instead of peripherally applied, have been unsuccessful for cut and color buffs. Hence there is a need for cut and/or color buffs having a pre-impregnated abrasive composition for buffing such that the need to apply buffing compound to the buffing wheel is substantially eliminated.
The present invention relates to self-contained fibrous buffing articles that are functional without the application of external buffing compounds to the periphery or surfaces of the buffing wheel. Hence, in one embodiment, the invention resides in a self-contained fibrous buffing article comprising at least one layer of a fibrous nonwoven fabric comprising lyocell fiber and having a hardened adherent coating comprising a crosslinked binder, abrasive particles, and a lubricant. The self-contained buff is capable of imparting bright finishes onto metal surfaces, has a long service life, and is resistant to fraying, dusting, smearing, and unraveling.



BRIEF DESCRIPTION OF THE DRAWINGS
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure, which broader aspects are embodied in the exemplary construction.
FIG. 1 illustrates one embodiment of a self-contained fibrous buffing article
FIG. 2 illustrates a second embodiment of a self-contained fibrous buffing article
FIG. 3 illustrates a third embodiment of a self-contained fibrous buffing article
FIG. 4 illustrates a fourth embodiment of a self-contained fibrous buffing article
FIG. 5 illustrates a fifth embodiment of a self-contained fibrous buffing article
FIG. 6 illustrates comparative testing results on a stainless steel workpiece
FIG. 7 illustrates comparative testing results on an aluminum workpiece
FIG. 8 illustrates comparative testing results on a brass workpiece



Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure.
Definitions
As used herein, “self-contained fibrous buffing article” means a buffing article containing a pre-applied or pre-impregnated abrasive buffing composition to the fibrous material forming the buffing article. The abrasive buffing composition is suitable for cut or color buffing, and is applied to the buffing article by the manufacturer during the initial manufacturing of the buffing article. As such, the application of a buffing compound to the buffing article by an operator before first using or while using the buffing article to buff a work surface is not required.
As used herein, “hardening”, when used to describe the solidification of a precursor, refers to curing (e.g., polymerization and/or cross-linking, thermally or otherwise), drying (e.g., driving off a volatile solvent) and/or simply by cooling.
As used herein, forms of the words “comprise”, “have”, and “include” are legally equivalent and open-ended. Therefore, additional non-recited elements, functions, steps or limitations may be present in addition to the recited elements, functions, steps, or limitations.
DETAILED DESCRIPTION
The self-contained fibrous buffing article comprises at least one layer of a fibrous nonwoven fabric impregnated with an adherent slurry comprising a crosslinkable binder precursor, abrasive particles, and a lubricant.
Fibrous Nonwoven Fabric
Nonwoven fabrics useful in the practice of this invention may be made by any known web formation system. In some embodiments, the fabric may be spunbonded, hydroentangled, or melt blown. In some embodiments, the nonwoven fabric is a dry laid nonwoven fabric. In some embodiments, the nonwoven fabric is an air-laid nonwoven fabric. In some embodiments, the nonwoven fabric is formed by carding and cross-lapping. While web formation methods using staple fibers are typical, continuous filament systems such as spunbond or meltblown may be used. Useful staple fibers lengths include those between 0.75 inch (19 mm) and 4 inches (102 mm), inclusive. In some embodiments, a prebond coating may be applied to enhance the integrity of the nonwoven fabric.
The fiber component of the nonwoven fabric may be synthetic, man-made, or natural in origin. Exemplary synthetic fibers are polyester (such as poly(ethylene terephthalate) or poly(butylene terephthalate)), polyamide (such as poly(hexamethylene adipate) or polycaprolactam), and polyolefins (such as polyethylene or polypropylene). Exemplary man-made fibers include cellulose acetate, rayon, and lyocell. In some embodiments, natural fibers such as cotton, jute, ramie, and wool are useful alone or in combination. In some embodiments, blends of two, three, or even more fiber constituents may be used.
In some embodiments, fiber denier may be greater than 0.1 denier (0.11 dtex). In some embodiments, fiber size may be less than 20 denier (22.5 dtex). In some embodiments, mixtures of two or more fiber deniers may be useful.
In some embodiments, the nonwoven fabric includes lyocell fiber. In some embodiments, the nonwoven fabric is at least 30 wt % lyocell fiber, or at least 50 wt % lyocell fiber, or at least 70 wt % lyocell fiber, or at least 90 wt % lyocell fiber, or even 100 wt % lyocell fiber. Other natural, manmade, or synthetic fibers may be also incorporated, including polyamide (e.g., nylon 6, nylon 6,6), polyester (e.g., polyethylene terephthalate, polybutylene terephthalate), rayon, cellulose acetate, or cotton. In some embodiments, the nonwoven fabric may contain melt-bondable fibers, including melt-bondable fibers that can be crosslinked after melt bonding to render them thermosetting.
The nonwoven fabric is prepared to have a basis weight from 50 g/m2 to 500 g/m2, or from 75 g/m2 to 400 g/m2, or from 100 g/m2 to 300 g/m2. The thickness of the nonwoven fabric is typically from 1 mm to 20 mm, or from 2 mm to 15 mm, or from 5 mm to 10 mm. In some embodiments, the nonwoven fabric is subsequently needle-tacked.
In other embodiments, the nonwoven fabric may be subsequently calendered and/or otherwise thermally-treated (e.g., through-bonding).
Adherent Slurry
The adherent slurry comprises an aqueous dispersion of abrasive particles, a lubricant, and a crosslinkable binder precursor. Useful adherent slurries are formulated to maximize the desired abrasive effects (cut or color buffing), maximize the buff's flexibility, and minimize both smearing (unwanted transfer of buffing components onto the workpiece) and dusting during use. Useful compositions of the adherent slurry are 3-50 wt. % binder precursor, 5-80 wt % lubricant, and 10-80 wt % mineral. The nonwoven fabric is coated with the adherent slurry and other optional additives in several coating steps. The coatings may be applied by any conventional means such as, for example, roll coating, spray coating, or saturation coating. In some embodiments, the coatings are applied in at least two separate steps with the binder precursor and mineral applied and then hardened followed by the lubricant coating and hardening. In some embodiments, four coatings are applied: a polyurethane coating followed by a hardening step; a lubricant coating; a phenolic resin coating followed by a hardening step; and a lubricant coating and hardening.
Crosslinkable Binder Precursors
Suitable binder precursors include polyurethane polymers or prepolymers, phenolic resins, and acrylics. Examples of useful urethane prepolymers include polyisocyanates and blocked versions thereof. Typically, blocked polyisocyanates are substantially unreactive to isocyanate reactive compounds (e.g., amines, alcohols, thiols, etc.) under ambient conditions (e.g., temperatures in a range of from about 20 degrees C. to about 25 degrees C.), but upon application of sufficient thermal energy the blocking agent is released, thereby generating isocyanate functionality that reacts with the amine curative to form a covalent bond.
Useful polyisocyanates include, for example, aliphatic polyisocyanates (e.g., hexamethylene diisocyanate or trimethylhexamethylene diisocyanate); alicyclic polyisocyanates (e.g., hydrogenated xylylene diisocyanate or isophorone diisocyanate); aromatic polyisocyanates (e.g., tolylene diisocyanate or 4,4′-diphenylmethane diisocyanate); adducts of any of the foregoing polyisocyanates with a polyhydric alcohol (e.g., a diol, low molecular weight hydroxyl group-containing polyester resin, water, etc.); adducts of the foregoing polyisocyanates (e.g., isocyanurates, biurets); and mixtures thereof.
Useful commercially available polyisocyanates include, for example, those available under the trade designation “ADIPRENE” from Chemtura Corporation, Middlebury, Conn. (e.g., “ADIPRENE L 0311”, “ADIPRENE L 100”, “ADIPRENE L 167”, “ADIPRENE L 213”, “ADIPRENE L 315”, “ADIPRENE L 680”, “ADIPRENE LF 1800A”, “ADIPRENE LF 600D”, “ADIPRENE LFP 1950A”, “ADIPRENE LFP 2950A”, “ADIPRENE LFP 590D”, “ADIPRENE LW 520”, and “ADIPRENE PP 1095”); polyisocyanates available under the trade designation “MONDUR” from Bayer Corporation, Pittsburgh, Pa. (e.g., “MONDUR 1437”, “MONDUR MP-095”, or “MONDUR 448”); and polyisocyanates available under the trade designations “AIRTHANE” and “VERSATHANE” from Air Products and Chemicals, Allentown, Pa. (e.g., “AIRTHANE APC-504”, “AIRTHANE PST-95A”, “AIRTHANE PST-85A”, “AIRTHANE PET-91A”, “AIRTHANE PET-75D”, “VERSATHANE STE-95A”, “VERSATHANE STE-P95”, “VERSATHANE STS-55”, “VERSATHANE SME-90A”, and “VERSATHANE MS-90A”).
To lengthen pot-life, polyisocyanates such as, for example, those mentioned above may be blocked with a blocking agent according to various techniques known in the art. Exemplary blocking agents include ketoximes (e.g., 2-butanone oxime); lactams (e.g., epsilon-caprolactam); malonic esters (e.g., dimethyl malonate and diethyl malonate); pyrazoles (e.g., 3,5-dimethylpyrazole); alcohols including tertiary alcohols (e.g., t-butanol or 2,2-dimethylpentanol), phenols (e.g., alkylated phenols), and mixtures of alcohols as described.
Exemplary useful commercially available blocked polyisocyanates include those marketed by Chemtura Corporation under the trade designations “ADIPRENE BL 11”, “ADIPRENE BL 16”, “ADIPRENE BL 31”, and blocked polyisocyanates marketed by Baxenden Chemicals, Ltd., Accrington, England under the trade designation “TRIXENE” (e.g., “TRIXENE BL 7641”, “TRIXENE BL 7642”, “TRIXENE BL 7772”, and “TRIXENE BL 7774”).
In some embodiments, the amount of urethane prepolymer present in a polyurethane binder coating is in an amount from 10 to 50 percent by weight, or from 15 to 40 percent by weight, or even from 15 to 35 percent by weight based on the total weight of the hardened coating composition, although amounts outside of these ranges may also be used.
Suitable amine curatives include aromatic, alkyl-aromatic, or alkyl polyfunctional amines, preferably primary amines. Examples of useful amine curatives include 4,4′-methylenedianiline; polymeric methylene dianilines having a functionality of 2.1 to 4.0 which include those known under the trade designations “CURITHANE 103”, commercially available from the Dow Chemical Company, and “MDA-85” from Bayer Corporation, Pittsburgh, Pa.; 1,5-diamine-2-methylpentane; tris(2-aminoethyl)amine; 3-aminomethyl-3,5,5-trimethylcyclohexylamine (i.e., isophoronediamine), trimethylene glycol di-p-aminobenzoate, bis(o-aminophenylthio)ethane, 4,4′-methylenebis(dimethyl anthranilate), bis(4-amino-3-ethylphenyl)methane (e.g., as marketed under the trade designation “KAYAHARD AA” by Nippon Kayaku Company, Ltd., Tokyo, Japan), and bis(4-amino-3,5-diethylphenyl)methane (e.g., as marketed under the trade designation “LONZACURE M-DEA” by Lonza, Ltd., Basel, Switzerland), and mixtures thereof. If desired, polyol(s) may be added to the hardenable composition, for example, to modify (e.g., to retard) cure rates as required by the intended use.
The amine curative should be present in an amount effective (i.e., an effective amount) to cure the blocked polyisocyanate to the degree required by the intended application; for example, the amine curative may be present in a stoichiometric ratio of curative to isocyanate (or blocked isocyanate) in a range from 0.8 to 1.35 or in a range from 0.85 to 1.20.
Phenolic materials are useful binder precursors because of their thermal properties, availability, cost, and ease of handling. Resole phenolics have a molar ratio of formaldehyde to phenol of greater than or equal to one, typically from 1.5:1.0 to 3.0:1.0. Novolac phenolics have a molar ratio of formaldehyde to phenol of less than 1.0:1.0. Examples of commercially available phenolics include those known by the trade names DUREZ and VARCUM from Occidental Chemicals Corp., RESINOX from Monsanto, AROFENE from Ashland Chemical Co., and AROTAP from Ashland Chemical Co.
In some embodiments, the amount of phenolic binder precursor present in the phenolic binder coating is in an amount from 2 to 50 percent by weight, or in an amount from 5 to 40 percent by weight, or even in an amount from 5 to 35 percent by weight based on the total weight of the coating composition, although amounts outside of these ranges may also be used.
Emulsions of crosslinked acrylic resin particles may also find utility in the present invention.
Some binder precursors include a phenolic mixed with a latex. Examples of such latexes include materials containing acrylonitrile butadiene, acrylics, butadiene, butadiene-styrene, and combinations thereof. These latexes are commercially available from a variety of different sources and include those available under the trade designations RHOPLEX and ACRYLSOL commercially available from Rohm and Haas Company, FLEXCRYL and VALTAC commercially available from Air Products & Chemicals Inc., SYNTHEMUL, TYCRYL, and TYLAC commercially available from Reichold Chemical Co., HYCAR and GOODRITE commercially available from B. F. Goodrich, CHEMIGUM commercially available from Goodyear Tire and Rubber Co., NEOCRYL commercially available from ICI, BUTAFON commercially available from BASF, and RES commercially available from Union Carbide.
Lubricant
Examples of lubricants for use in the self-contained fibrous buffing article include fatty acids (e.g., stearic acid), metallic salts of fatty acids (e.g., lithium stearate, zinc stearate), solid lubricants (e.g., poly(tetrafluoroethylene) (PTFE), graphite, and molybdenum disulfide), mineral oils and waxes (including micronized waxes), carboxylic acid esters (e.g., butyl stearate), polyethylene glycol distearate (e.g., PEG 6000 distearate), poly(dimethylsiloxane) fluids, poly(dimethylsiloxane) gums, and combinations thereof. Such lubricants and commercial sources are known in the art. Other suitable lubricants may be apparent to those skilled in the art after reviewing the present disclosure. Useful lubricants include, for example, “INDUSTRENE 4516” (from PCM Biogenics, Memphis, Tennesee), “LIC17” (from Ashland, Inc., Covington, Ky.), mineral oil (from Univar USA, Redmond, Wash.), “ZINCUM SW”, “ZINCUM AV”, “CEASIT SW” and “CEASIT AV” (from Baerlocher Do Brasil S.A, Americana, SP, Brazil), “COMAX A”, “COMAX T”, “QUIMIPEL COAT 9327” and “QUIMIPEL COAT 9330” (from Quimipel Industria Quimica LTDA, Piracaia, SP, Brazil), “Natural Graphite” (from Nacional de Grafite LTDA, Itapecerica, MG, Brazil), “Mineral Oil USP Grade Agecom and Drakeol” (from Agecom Produtos de Petroleo, Maud, SP, Brazil).
Abrasive Particles
Suitable abrasive particles are those useful in buffing operations. The abrasive particles may be of any suitable composition, but those comprising chromium oxide, titanium oxide, aluminum oxide, calcined micronized aluminum oxide, iron oxide or silicon carbide are typical. Appropriate abrasive particle size distributions include those with median particle diameters of no greater than 50 micrometers, no greater than 30 micrometers, or no greater than 15 micrometers.
Examples of useful abrasive particles include “E2616 GREEN” (from Akrochem Corporation, Akron, Ohio), “KRONOS 2310” (from Kronos Inc., Houston, Tex.), “BK-5099” (from Elementis Pigments Inc., Fairview Heights, Ill.), “MICROGRIT WCA” (from Micro Abrasives Corporation, Westfield, Mass.), and combinations thereof.
Other Optional Additives
Other optional additives that may be beneficial in the adherent slurry include surfactants, wetting agents, antifoaming agents, colorants, coating modifiers, and coupling agents.
An anionic surfactant is beneficial to incorporate the lubricant into the adherent slurry. An example of an effective anionic surfactant is sodium dioctyl sulfosuccinate, available as “Aerosol OT-75” from Cytec Do Brasil Ltda., Sao Paulo, SP, Brazil. Useful emulsifiers are triethanolamine, such as that available as “AMP-95” from Angus Chemical Company, Buffalo Grove, Ill., and simple polyol compounds such as glycerin, from Acme Hardesty Oleochemicals, Blue Bell, Pa.
A wetting agent is useful to promote impregnation of the fibrous buffing material with the adherent slurry. Useful wetting agents include surfactants that are at least partially non-ionic, such as “NopcoWet BR”, available from Gap Quimica Ltda., Guarulhos, SP, Brazil. Other useful nonionic surfactants include “TERGITOL 15-S-40” and “TERGITOL XJ”, both from Dow Chemical, Midland, Mich., and “PEG DS6000” available from BASF, Florham Park, N.J.
Coating modifiers and VOC reducers such as hydroxyethyl ethylene urea are useful to promote film formation. Useful coating modifiers include “SR-511” available from Sartomer Company, Exton, Pa.
A coupling agent is useful to improve adhesion between the nonwoven buffing material, the binder, and the abrasive mineral. Useful coupling agents include “Z-6020 Silane” and “Z-6040 Silane”, both available from Dow Corning, Midland, Mich.
Colorants or pigments such as iron oxide, titanium oxide, or carbon black may be added to visually identify different buffing articles and/or type of buffing article. In some embodiments, pigments such as chromium oxide may also serve as an abrasive particle.
Suitable colorants pigments include “KRONOS 2310” (Kronos Inc., Houston, Tex.), “E2616 GREEN” (Akrochem Corporation, Akron, Ohio), “BK-5099 PIGMENT”
(Elementis Pigments Inc., Fairview heights, Ill.), and “Copperas Red Iron Oxide RS098D” (Rockwood Pigments Inc., Beltsville, Md.)
Adherent Slurry Impregnation Process
The self-contained fibrous buffing articles are made by impregnating a length of suitable fibrous nonwoven fabric with an adherent slurry comprising abrasive particles, crosslinkable binder, a lubricant, and optionally a wetting agent and/or a surfactant, followed by a hardening step forming a hardened adherent coating on the fibers and surfaces of the nonwoven fabric. The adherent slurry may be incorporated into the fibrous material in one or more steps with either one or more hardening steps as previously discussed. In some embodiments, an adherent slurry is incorporated and hardened, followed a subsequent coating comprising additional lubricant, followed by an additional hardening step. Adherent slurries and additional coatings may be applied by conventional application means, such as roll coating, curtain coating, die coating, or spraying.
In some embodiments, the total dry add-on weight of the coating(s) is from 50 g/m2 to 500 g/m2, or from 50 g/m2 to 300 g/m2, or from 100 g/m2 to 200 g/m2. In some embodiments, the total weight of the final coated buffing fabric is from 200 g/m2 to 1000 g/m2.
During the hardening step(s), as water is removed, it has been discovered that more desirable adherent slurries separate into a hydrophilic phase and a lipophilic phase. While not wishing to be bound by theory, the inventors believe that the partitioning of the various coating constituents into these discrete phases contributes to superior buffing performance when using the self-contained fibrous buffing article.
Self-Contained Fibrous Buffing Articles
The buff must not only be capable of withstanding the strenuous use conditions typically encountered in buffing operations, but it must also be capable of holding the adherent buffing composition on the buffing surface. Self-contained fibrous buffing articles may be any design or style presently known or contemplated in the future. The most popular forms of buffs are depicted by FIGS. 1-3.
FIG. 1 shows a buff 10 composed of layers 11 of fibrous buffing material, optionally sewn with one or more circles of stitching 12 with suitable thread which is known for this purpose between the outer edge 13 and central opening 14 for attachment to a rotating spindle or mandrel. Layers of fibrous buffing material have a generally circular shape and they are stacked (or the entire assembly is cut) so that the edges of each of the layers define a cylindrical surface which is the peripheral edge of the buff.
FIG. 2 shows a buff 20 composed of layers 21 of fibrous buffing material sewn together with several circular patterns 22 of stitching with suitable thread. The sewing pattern may be concentric (as shown), spiral, square, radial, radial arc, or combinations thereof. Buff 20 has a central opening 24 for attachment to a rotating spindle or mandrel.
FIG. 3 depicts what is known as a “puckered” buff 30 which is produced by cutting a continuous strip of fibrous buffing material and convolutely wrapping this strip around the separated ends of axially aligned cylindrical mandrels, radially constricting the wrapped strip at its middle to form a flattened “puckered” annulus, and installing a rigid clinch ring 33 of either plastic or metal within the opening of the annulus. A “puckered” fibrous buffing material annulus may also be fastened by stapling, sewing or adhesive bonding to a suitable rigid annulus such as an annulus formed of cardboard.
The particular construction of a sewn buff will depend upon its ultimate use. Buffs formed of layers of fabric, which are sewn together, as shown in FIG. 2 are typically used for cut buffing. Very close rows of stitching increase the stiffness of the sewn buff to increase cut. The sewing patterns for such buffs may vary, depending upon the needs of the user, from concentric sewn, radial sewn, square sewn, spiral sewn, to radial arc sewn and radial arc with spiral center. Concentric sewing results in non-uniform density when the buff wears as it is used. As the buff wears closer to the stitches, the buff will become harder and just past a row of stitches it becomes softer. Spiral sewing results in a more uniform density, although the buff surface will still have a density variation. Square and non-concentric sewing patterns produce pockets that may aid in the buffing process.
The puckered or pleated buff is popular for its cool running capability, provided by pleats or puckers in its fabric. The type of the construction of a puckered buff depends upon its ultimate use also. Different hardnesses may be required for various cutting and/or color buffing applications. Hardness may be controlled somewhat by the spacing of buffs on the mandrel, but more commonly is regulated by the degree of puckering, the diameter of the buff relative to the clinch ring diameter, or the stiffness of the buff fabric.
Other self-contained fibrous buffing articles may also find utility, including “flap wheel” constructions 40 as illustrated in FIG. 4 having individual buffing flaps 41, or “flap belt” constructions 50 as illustrated in FIG. 5 having individual buffing flaps 51. Buffing articles such as needletacked belts or discs may also find utility.
EXAMPLES
Objects and advantages of this invention are further illustrated by the following non-limiting examples; however, the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this invention. Unless otherwise noted, all parts, percentages, ratios, etc. in the Examples and the rest of the specification are by weight. The following abbreviations are used throughout the Examples.







TABLE 1







ABBREVIATION INDEX








Abbreviation
Description





T15
surfactant, available from Dow, Midland, Michigan as



“TERGITOL 15-S-40”


PEG
Surfactant, available from BASF, Florham Park, New



Jersey as “MAPEG DS6000”


TEA
Triethanolamine, available from Angus Chemical



Company, Buffalo Grove, Illinois


Glycerin
Polyol, obtained from Acme Hardesty Oleochemicals,



Blue Bell, Pennsylvania


CrO
Chromium oxide abrasive, obtained from Akrochem



Corporation, Akron, Ohio as “E2616 Green”


TiO
Kronos 2310, titanium dioxide pigment, obtained from



Kronos Inc. Houston, TX


FeO
Black iron oxide, BK-5099 Pigment, obtained from



Elementis Pigments Inc. Fairview Heights, IL


WCA
“MICROGRIT WCA #3”, aluminum oxide powder



having an average particle size of 3.25 micrometers,



obtained from Micro Abrasives Corporation, Westfield,



MA


CrO/TiO
Abrasive particle blend, 50.0% Cr2O3 and 50.0% TiO2 by



weight


FeO/WCA
Abrasive particle blend, 25.0 wt % Fe2O3 and 75.0 wt %



WCA


SA
Stearic acid, obtained from PMC Biogenics, Memphis,



Tennessee as “INDUSTRENE 4516”


LiSt
Lithium stearate lubricant, obtained from Ashland, Inc.,



Covington, Kentucky as “LIC17”


MO
Mineral oil, obtained from Univar USA, Redmond,



Washington


BL16
Polyurethane prepolymer, obtained from Chemtura



Group, Middlebury, Connecticut as “ADIPRENE BL-16”


TXJ
Surfactant, available from Dow Chemical, Midland,



Michigan as “TERGITOL XJ”


KAA
Amine curing agent, available from Nippon Kayaku



Company, Ltd, Tokyo, Japan as “KAYAHARD AA”


SR511
Hydroxyethyl ethylene urea, available from Sartomer



Company, Inc, Exton, Pennsylvania as “SR-511 A”


Arofene
Phenolic resin, obtained from Ashland Inc., Covington,



Kentucky as “AROFENE 72155 W55”


Lyocell
Lyocell staple fiber, 1.7 dtex × 38 mm, available from



Lenzing Fibers, Lenzing, Austria as “Tencel HS 260”


Nylon
Polyamide staple fiber, nylon 6,6, “Type 501, 15 Denier



1.5 inch cut length, merge 153 × 90”, obtained from



Invista, Wichita, KS


W-290H
“WITCOBOND W-290H” aqueous polyurethane



dispersion, obtained from Chemtura, Middlebury,



Connecticut


GL-720
“RHOPLEX GL-720”, water based acrylic, obtained



from Rhom and Haas Philadelphia PA
















TABLE 2







COATING FORMULATIONS










Material
Coating 1, %
Coatings 2 & 4, %
Coating 3, %













Water
77.6
65.5
58.4


T15
1.3
1.5
1.6


PEG
1.0
1.0
1.1


TEA
0.2
0.6
0.6


Glycerin
1.2
3.7
3.9


CrO
5.2
9.2
9.7


TiO
5.2
9.2
9.7


SA
2.4
7.7
8.1


LiSt
0.6
0.4
0.4


MO
1.1
1.0
1.1


BL16
3.7
0.0
0.0


TXJ
0.1
0.0
0.0


KAA
0.6
0.0
0.0


SR511
0.0
0.2
0.2


Arofene
0.0
0.0
5.0
















TABLE 3







COATING FORMULATIONS











Material
Coating 1, %
Coating 2, %
Coating 3, %
Coating 4, %














Water
71.0
71.4
55.5
58.8


T15
1.7
2.0
1.7
2.6


PEG
0.2
0.3
0.3
0.4


TEA
0.2
0.8
0.7
1.1


Glycerin
1.5
4.9
4.3
6.5


FeO
2.4
1.6
1.7
1.3


WCA3
7.3
4.9
5.2
3.9


SA
3.2
10.2
9.0
13.6


LiSt
0.7
1.2
1.1
1.6


MO
1.4
2.4
2.2
3.2


BL16
8.7
0.0
0.0
0.0


TXJ
0.2
0.0
0.0
0.0


KAA
1.3
0.0
0.0
0.0


SR511
0.0
0.3
0.3
0.4


Arofene
0.0
0.0
18.0
0.0


W290H
0.0
0.0
0.0
2.2


GL720
0.0
0.0
0.0
4.3
















TABLE 4







COATING FORMULATIONS












Material
Coating 1, %
Coatings 2 & 4 %
Coating 3, %
















Water
64.0
61.0
51.0



T15
1.8
0.3
0.3



PEG
1.8
1.2
1.3



TEA
0.2
0.7
0.8



Glycerin
1.3
4.3
4.6



CrO
17.8
21.5
22.9



SA
2.7
9.0
9.5



LiSt
1.1
0.5
0.5



MO
1.8
1.2
1.3



BL16
6.4
0.0
0.0



TXJ
0.2
0.0
0.0



KAA
1.0
0.0
0.0



SR511
0.0
0.3
0.3



Arofene
0.0
0.0
7.6










Examples 1-4
Examples 1-4 were prepared to demonstrate various embodiments of the self-contained fibrous buffing article.
Example 1
The self-contained fibrous buffing article of Example 1 was prepared to compare its ability to refine a metallic surface to that of current buffing articles. A 130 g/m2 airlaid nonwoven fabric was prepared from 100% Lyocell fibers (see materials description in Table 1) and needletacked to produce a 4.5 mm thick fabric. Coating 1 (coatings are described in Table 2) was applied (all coatings were applied via a roll coater) to a wet add-on of 301 g/m2 and heated 5 minutes at 160 degrees C. Coating 2 was then applied to a wet add-on of 399 g/m2 and heated 5 minutes at 140 degrees C. Coating 3 was then applied to achieve a wet add-on of 491 g/m2 and heated 5 minutes at 176 degrees C. Finally, Coating 4 was applied to a wet add-on of 465 g/m2 and heated 5 minutes at 140 degrees C.
The cumulative dry coated fabric weight was 386 g/m2 and the final thickness varied between 2.8 and 3.5 mm. The coated fabric was then converted into 10 inch diameter discs by die cutting and the resulting discs were evaluated using the Buffing Test.
Example 2
Example 2 was prepared identically to Example 1 except that a 167 g/m2 fabric of 75/25 wt % blend of lyocell/nylon staple fiber was substituted for 100% lyocell staple fiber and the final weight was 473 g/m2.
Example 3
Example 3 was prepared identically to Example 1 except that a 280 g/m2 fabric of 90/10 wt % blend of lyocell/nylon staple fiber was substituted for the 130 g/m2 fabric of 100% lyocell staple fiber, the abrasive particles in the coatings were FeO/WCA instead of CrO/TiO, the coatings were those indicated in Table 3, and the final weight was 900 g/m2.
Example 4
Example 4 was prepared identically to Example 1 except that a 285 g/m2 fabric of 90/10 wt % blend of lyocell/nylon staple fiber was substituted for the 130 g/m2 fabric of 100% lyocell staple fiber, the abrasive particles in the coatings were CrO instead of CrO/TiO, the coatings were those indicated in Table 4 and the final weight was 826 g/m2.
Comparative Examples A through D
Comparative Examples A through D were commercially available buffing articles, all of which required the use of an external buffing compound. A preliminary evaluation of seven commercially available buffing compounds was made. The top-performing three for each type of metal were chosen for the comparative examples.
Comparative Example A was an 80-ply spiral-sewn cotton wheel (part number SSCW1080, obtained from Caswell Electroplating, Lyons, N.Y.). Comparative Example A was used with a white rouge bar compound (White Rouge WBC5, obtained from Caswell Electroplating, Lyons, N.Y.).
Comparative Example B was a 40-ply loose cotton wheel (part number LCW1020 from Caswell Electroplating, Lyons, N.Y.). Comparative Example B was used with a jeweler's rouge buffing compound (Red Rouge JRBC5, obtained from Caswell Electroplating, Lyons, N.Y.).
Comparative Example C was identical to Comparative Example B, except that a green rouge bar buffing compound (Green Rouge SSBC5, obtained from Caswell Electroplating, Lyons, N.Y.) was substituted for the jeweler's rouge.
Comparative Example D was identical to Comparative Example B, except that a blue rouge buffing compound (Blue Rouge BLUBC5, obtained from Caswell Electroplating, Lyons, N.Y.) was substituted for the jeweler's rouge.
Buffing Test
The Buffing Test measured the efficacy of self-contained fibrous buffing articles and comparative buffing articles to modify the gloss of metallic substrates. Buffing efficacy was determined by the change in light reflectance as measured by a micro gloss meter (model AG-4446, obtained from Byk-Gardner USA, Columbia, Md.).
The workpieces were 12 inch×12 inch (30.5 cm×30.5 cm) sheets of 16 gauge 304 stainless steel, 1⁄8 inch (3.175 mm) thick 6061 aluminum, and 1/16 inch (1.5875 mm) thick brass alloy 353. Self-contained fibrous buffing articles were prepared for testing by stacking 12 discs of each Example and providing an arbor hole for mounting. Buffing articles of the Comparative Examples were tested as received. All buffing articles were 10 inches (25.4 cm) in diameter.
Buffing articles to be tested were mounted on an electric rotary tool that was disposed over an X-Y table. A stainless steel, aluminum, or brass workpiece was secured to the X-Y table. Then the table was set to traverse a 9-inch (23 cm) path at 5.6 inches/sec (14.2 cm/sec) forward in the +X direction and back the same distance and at the same speed in the −X direction, in a back and forth movement for 24 times all together (24 passes), then move 0.25 inch (6.35 mm) in the +Y direction, then traverse a 9-inch (23 cm) path at 5.6 inches/sec (14.2 cm/sec) forward in the +X direction and back the same distance and at the same speed in the −X direction, in a back and forth movement for 16 times (16 passes) all together, then move 0.25 inch (6.35 mm) in the +Y direction, then traverse a 9-inch (23 cm) path at 5.6 inches/sec (14.2 cm/sec) forward in the +X direction and back the same distance and at the same speed in the −X direction, in a back and forth movement for 8 times (8 passes) all together, then move 0.25 inch (6.35 mm) in the +Y direction, then traverse a 9-inch (23 cm) path at 0.6 inches/sec (14.2 cm/sec) forward in the +X direction and back the same distance and at the same speed in the −X direction, in a back and forth movement for 4 times (4 passes) all together, then move 0.25 inch (6.35 mm) in the +Y direction, then traverse a 9-inch (23 cm) path at 5.6 inches/sec (14.2 cm/sec) forward in the +X direction and back the same distance and at the same speed in the −X direction, in a back and forth movement for 2 times (2 passes) all together. This combination of motions defined one test cycle. The rotary tool was activated to rotate at 2200 rpm under no load. The buffing article was then urged radially against the workpiece at 0.5 psi (3.45 kPa) with its axis of rotation parallel to the X direction and the X-Y table was activated to move through the prescribed path.
Each buffing article was tested for 2, 4, 8, 16 and 24 cycles. A 20 degree gloss was measured after 2, 4, 8, 16, and 24 cycles. The 20 degree gloss after 24 test cycles for inventive and comparative articles is shown in Table 5. Incremental gloss change after 2, 4, 8, 16, and 24 cycles for inventive and comparative articles is shown in FIGS. 6 through 8. FIG. 6 shows the test results on a stainless steel workpiece. FIG. 7 shows the test results on an aluminum workpiece. FIG. 8 shows the test results on a brass workpiece. In every case the buffing articles of the invention have the same or higher gloss values than the comparative buffing articles used with externally applied buffing compounds. The self-contained fibrous buffing articles frequently achieved the desired gloss level at fewer passes than the comparative buffing articles.
Other modifications and variations to the present disclosure may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present disclosure, which is more particularly set forth in the appended claims. It is understood that aspects of the various embodiments may be interchanged in whole or part or combined with other aspects of the various embodiments. All cited references, patents, or patent applications in the above application for letters patent are herein incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control. The preceding description, given in order to enable one of ordinary skill in the art to practice the claimed disclosure, is not to be construed as limiting the scope of the disclosure, which is defined by the claims and all equivalents thereto.







TABLE 5







RESULTS









Gloss units












Example
Stainless Steel
Aluminum
Brass







1
1082
1474
1496



2
1116
1424
1485



3
1061
n.d.
n.d.



4
n.d.1
1505
1534



Comp. A
 973
n.d.
n.d.



Comp. B
1007
1158
1414



Comp. C
1024
1257
1384



Comp D
n.d.
1504
1397







1n.d. = not determined

## Claims

1. A self-contained fibrous buffing article comprising:
a buffing article that has at least one layer of a fibrous nonwoven fabric comprising lyocell fiber; and
a pre-applied or pre-impregnated abrasive buffing composition that is a hardened adherent coating comprising a crosslinked binder, abrasive particles, and a lubricant.

2. The self-contained fibrous buffing article of claim 1 wherein an adherent slurry applied to the nonwoven fabric which forms the hardened adherent coating comprises a surfactant.

3. The self-contained fibrous buffing article of claim 2 wherein the adherent slurry applied to the nonwoven fabric which forms the hardened adherent coating comprises a wetting agent.

4. The self-contained fibrous buffing article of claim 1 wherein the fibrous nonwoven fabric comprises a basis weight from 50 grams per square meter to 500 grams per square meter.

5. The self-contained fibrous buffing article of claim 1 wherein the abrasive particles have a mean particle size of no more than 50 micrometers.

6. The self-contained fibrous buffing article of claim 1 wherein the lubricant comprises stearic acid.

7. The self-contained fibrous buffing article of claim 1 wherein the lubricant comprises mineral oil.

8. The self-contained fibrous buffing article of claim 1 wherein the lubricant comprises stearic acid and mineral oil.

9. The self-contained fibrous buffing article of claim 5 wherein the abrasive particles comprise at least one of chromium oxide, aluminum oxide, titanium dioxide, or silicon carbide.

10. The self-contained fibrous buffing article of claim 1 wherein the fibrous nonwoven fabric comprises at least 70 wt % lyocell staple fibers.

11. The self-contained fibrous buffing article of claim 1 wherein the lyocell fiber comprises lyocell staple fibers that are airlaid and needletacked to form the fabric.

12. The self-contained fibrous buffing article of claim 1 wherein the at least one layer of the fibrous nonwoven fabric has a thickness in the range of 1 to 20 mm.

13. The self-contained fibrous buffing article of claim 1, wherein the buffing article comprises two or more layers of the fibrous nonwoven fabric.

14. The self-contained fibrous buffing article of claim 1 wherein the fibrous nonwoven fabric comprises a central opening.

15. The self-contained fibrous buffing article of claim 1 wherein a total dry add-on weight of the coating is in the range of 200 to 1000 g/m2.

16. The self-contained fibrous buffing article of claim 1 wherein the coating is formed from a slurry comprising separate hydrophilic and lipophilic phases.

17. The self-contained fibrous buffing article of claim 1 wherein the coating is formed from a slurry comprising 3-50 wt-% binder, 5-80 wt-% lubricant, and 10-80 wt-% abrasive particles.