JP2009534202A - Embossed structure abrasive article and method for producing and using the same - Google Patents

Abstract

  An embossed structured abrasive article having an inelastic high density thermoplastic film substrate and a structured abrasive layer is disclosed. Both the substrate and the structured abrasive layer have superimposed embossing features. Also disclosed are methods of making and using embossed structured abrasive articles.

Description

  The appearance in the glossy surface finish is important in the manufacture and repair of articles having such a surface finish. Examples of finishes used to make glossy surfaces include automotive and marine clearcoat finishes, lacquer finishes, and the like. During the implementation of such finishes, dust particles are mistakenly contained within the finish (usually referred to as “dust nibs”). These dust nibs impair the aesthetics in the finish and require one or more additional steps to reduce or eliminate (ie, denibing).

  Over the years, a type of abrasive article, commonly known as a “structured abrasive” article, is commercially available for use in manufacturing and repairing glossy surfaces, for example, for automobiles, trucks, boats, and the like. Yes.

  The structured abrasive article has a structured abrasive layer that is secured to a substrate and is typically used in combination with a liquid, such as water, optionally containing a surfactant, for example. The structured abrasive layer has a plurality of shaped abrasive composites (typically having fine dimensions), each having an abrasive article and a binder. In many cases, this shaped abrasive composite is precision shaped, for example, according to various geometric shapes (eg, pyramid shapes). An example of such a structured abrasive article is that sold under the trade designation “TRIZACT” by 3M Company of St. Paul, Minnesota.

  In many cases, conventional structured abrasive articles are used in a wet polishing process that is typical in the industry unless a special design or process is employed to solve the problem of "stiction", i.e., the problem. However, there is a problem with the tendency of the abrasive surface to stick to the workpiece. Static friction makes it difficult to control a polishing process that requires more force to move and control a conventional structured abrasive article, thereby destabilizing the control of any abrasive tool attached, and the abrasive tool When it reaches unintended areas such as side view mirrors or body shaping, it can ultimately result in damage to the workpiece (eg, car). Static friction is often broken in an uncontrolled manner and often suddenly releases the structured abrasive article from the abrasive substrate. This usually occurs at the same time that the structured abrasive article is released and actually slips easily over the surface of the workpiece with little polishing.

  Structured abrasive articles (eg, discs) are often used in combination with a compressible backup pad (eg, foam or nonwoven) and attached to a tool (eg, a disc sander). In such applications, structured abrasive articles typically have an attached boundary layer (eg, a hooked fabric or adhesive) that is used to secure them to a backup pad during use. The compressibility of the backup pad provides a degree of flexibility that can help the abrasive article, for example, polish a curved surface. In the case of a hand held structured abrasive article (eg, a dennibing disc), the foam layer may be included in the structure of the article itself to provide conformance. However, the presence of a compressed layer of foam or nonwoven can cause the structured abrasive article to ride on surface defects such as dust nibs and, in rare cases, simply roll without removing them.

  Further, during polishing of a structured abrasive article having a structured abrasive layer secured to a foam layer, the abrasive article can be subjected to severe forces that cause breakage when the abrasive layer can be used elsewhere. For example, such initial failure can be caused by separation of the abrasive layer from the foam substrate and / or damage caused to the foam substrate.

In certain embodiments, the present invention provides:
A substrate having first and second major surfaces and comprising an inelastic high density thermoplastic film;
An optional adhesive layer in contact with the first major surface, having the same extent and being fixed;
A structural polishing layer that is in contact with the first surface of the substrate or an optional adhesive layer, is coextensive, and is fixed. The structural polishing layer is composed of abrasive particles and a binder, and protrudes outward. An embossed structure consisting of a precision shaped abrasive composite, where both the substrate and the structured abrasive layer have overlapping embossing features, and an optional attached boundary layer secured to the second major surface An abrasive article,
The embossed structured abrasive article relates to an embossed structured abrasive article that does not include a porous elastic element.

In another aspect, the invention relates to a method for polishing a workpiece, the method comprising:
a) providing an embossed structured abrasive article according to the present invention;
b) providing a workpiece having a reinforced polymer layer thereon;
c) frictionally contacting at least a portion of the structured polishing layer with the polymer layer; and d) moving at least one of the workpiece and the structured polishing layer relative to the other to polish at least a portion of the polymer layer. And a method including the steps.

In yet another aspect, the invention relates to a method of manufacturing an embossed structured abrasive article, the method comprising:
Providing a substrate having first and second major surfaces and comprising an inelastic high-density thermoplastic film;
Fixing the adhesive layer in contact with the first main surface and having the same spread;
A process of fixing the structural polishing layer in contact with the adhesive layer and fixing it so as to have the same spread, and this structural polishing layer includes abrasive particles and a binder and is precisely shaped to protrude outwardly. Consist of body,
Embossing the substrate and the structured polishing layer to provide an embossed feature of superposition in the substrate and the structured polishing layer;
Optionally fixing a mounting boundary layer to the second major surface,
Thereby, an embossed structured abrasive article free of porous elastic elements is provided.

In yet another aspect, the present invention provides a method of manufacturing an embossed structured abrasive article, the method comprising:
Providing an inelastic high density thermoplastic film substrate having first and second major surfaces;
A process of fixing a structural polishing layer to a substrate, wherein the structural polishing layer is in contact with an adhesive layer, is coextensive, includes abrasive particles and a binder, and is precisely shaped to protrude outwardly. Consisting of a complex,
Embossing the substrate and the structured polishing layer to provide an embossed feature of superposition in the substrate and the structured polishing layer;
Optionally attaching an attached boundary layer to the second major surface, thereby providing an embossed structured abrasive article that does not include a porous elastic element.

  Structured abrasive articles according to the present invention typically exhibit a combination of abrasive and static friction properties that favor dennibing in a glossy finish.

In this application:
“Fixed” applied to any two components means that it cannot be easily separated.

  In an abrasive layer or substrate, “embossed features” relate to features that appear raised or depressed relative to respective adjacent surfaces of the abrasive layer or substrate, and do not include features due to the shape of the individual abrasive composites themselves.

  “Embossing” is formed in a process in which the patterned surface of the tool is pressed against the object at a sufficient pressure and optionally a sufficient temperature to give the object a recognizable reverse pattern. Means.

  “High density” means substantially free of enclosed voids or pores. The high density film can have perforations in place.

  “Inelastic” means that after stretching or expanding to at least 10 percent, it does not easily return to its original shape.

  “Precisely shaped abrasive composite” refers to an abrasive composite, the shape of the abrasive composite having discrete length edges with discrete endpoints, for example, as defined by the intersection of various sides. Defined by sides having a relatively smooth surface defined and bonded by well-defined edges. The terms “defined” and “boundary” relate to the exposed surfaces and edges of the polishing composite that delimit and define the actual three-dimensional shape of each polishing composite. These boundaries are recognized and identified when observing a cross section of the abrasive article with a scanning electron microscope. These boundaries separate and distinguish precisely shaped abrasive composites from each other, even when the composites are adjacent to each other along their boundaries at their bottom. By comparison, in abrasive composites that do not have a precise shape, the boundaries and edges are not well defined (eg, when the abrasive composite is flexed before curing is complete).

  “Elastic” means that it can return to its original shape or position, such as after being compressed.

  Referring now to FIGS. 1A and 1B, an exemplary embossed structured abrasive article 100 comprises an inelastic high density thermoplastic film substrate 110 having a first major surface 117 and a second major surface 115. The optional adhesive layer 120 is in contact with the first major surface 117, is fixed, and is coextensive. The structured polishing layer 130 is in contact with either the first major surface 117 (if the optional adhesive layer 120 is not present) or the optional adhesive layer 120 (if present) of the film substrate 110 and is coextensive. . The structured abrasive layer 130 comprises an abrasive composite 135 (shown in FIG. 1B) that includes abrasive particles 137 and a binder 138 and is precision shaped to protrude outwardly. Both the film substrate 110 and the structured polishing layer have a superposed embossing feature 150. An optional attached boundary layer 140 is secured to the second major surface 115. The embossed structure abrasive article 100 does not include a porous elastic component.

  Another representative embossed structured abrasive article is shown in FIG. A representative embossed structured abrasive article 200 comprises an inelastic high density thermoplastic film substrate 210 having a first major surface 217 and a second major surface 215, respectively. The optional adhesive layer 220 is in contact with and fixed to the first main surface 217 and has the same spread. The structured polishing layer 230 contacts and is fixed to either the first major surface 217 of the film substrate 210 (optionally if the adhesive layer 220 is not present) or optionally the adhesive layer 220 (if present); Have the same spread. The structured abrasive layer 230 comprises an abrasive composite 135 (shown in FIG. 1B) that includes abrasive particles 137 and a binder 138 and is precision shaped to protrude outwardly. Both film substrate 210 and structured polishing layer 230 have superimposed embossing features 250. Optional attached boundary layer 240 is secured to second major surface 215. The embossed structured abrasive article 200 does not include a porous elastic component.

  Various shaped features can be embossed into the abrasive layer to make an embossed structured abrasive article according to the present invention. In general, the structural polishing layer is continuous, however, depending on the dimensions of the embossing features and their sharpness, for example, as a result of the embossing process, the polishing layer has a substantially continuous stress crack. Or may be substantially vertically discontinuous.

  In one embodiment (shown in FIG. 3), an exemplary embossed structured abrasive article 300 includes a structured abrasive layer 360 comprising overlapping dimples 350 that are embossed on the structured abrasive layer 360, and an inelastic high-density thermoplastic film. It has a substrate 310 (details not shown).

  In another embodiment (shown in FIG. 4), an exemplary embossed structured abrasive article 400 includes a structured abrasive layer 460 comprising a structured abrasive layer 460 and an overlay post 450 embossed on the structured abrasive layer 460, and a non- It has an elastic high-density thermoplastic film substrate 410 (details not shown).

  In yet another embodiment (shown in FIG. 5), an exemplary embossed structured abrasive article 500 includes a structured abrasive layer 530 that is undulated and embossed in a superposed form on the structured abrasive layer 530, and an inelastic high density It has a thermoplastic film substrate 510 (details not shown).

  The embossed structured abrasive article according to the present invention does not include an elastic compression layer such as a foam. Advantageously, this alleviates the problem of delamination between the elastic compression layer and other layers such as, for example, a structural abrasive member during a polishing process, and the problems that continue to bother such abrasive articles.

  The substrate is an inelastic high density thermoplastic film that includes a thermoplastic polymer that may contain various additives. Examples of suitable additives include colorants, processing aids, reinforcing fibers, heat stabilizers, UV stabilizers, and antioxidants. Examples of useful fillers include clay, calcium carbonate, glass beads, talc, clay, mica, wood flour, and carbon black. The substrate can be a composite film, such as a coextruded film having two or more separate layers.

  Suitable thermoplastic polymers include, for example, polyolefins (eg, polyethylene and polypropylene), polyesters (eg, polyethylene terephthalate), polyamides (eg, nylon-6 and nylon-6,6), polyimides, polycarbonates, and the like And combinations thereof.

  Typically, the average thickness of the substrate is at least within the range of 25 micrometers (1 mil) to 2500 micrometers (100 mils), although thicknesses outside this range may also be used. Of course, the thickness of the substrate can vary depending on the result of the embossing, for example.

  The optional adhesive layer can be any adhesive material that is strong enough to maintain adhesion of the polishing layer to the substrate during the polishing process. Examples of suitable adhesives include hot melt adhesives, pressure sensitive adhesives (eg, latex pressure sensitive adhesives or pressure sensitive adhesive transfer films), thermosetting thermoplastic adhesives, and glues.

  The structural abrasive layer typically comprises an abrasive composite that includes abrasive particles and a binder and is irregularly shaped to project outwardly. As used herein, the term “abrasive composite” refers to a body that includes abrasive particles dispersed in a binder. The structured abrasive layer may be continuous or discontinuous and may have, for example, areas where there is no shaped abrasive composite. Usually, but not necessarily, the shaped abrasive composite is disposed on a substrate according to a predetermined pattern or arrangement.

  The shaped abrasive composites can have substantially the same shape and / or dimensions, or a mixture of various shapes and / or dimensions.

  In certain embodiments, at least a portion of the shaped abrasive composite may include a “precisely shaped” abrasive composite. This is defined and bonded by well-defined edges, with the shaped abrasive composite having discrete length edges with discrete endpoints, as defined by the intersection of the various sides. Means defined by a side surface having a relatively smooth surface. The terms “defined” and “boundary” relate to the exposed surfaces and edges of the composite that delimit and define the actual three-dimensional shape of each shaped abrasive composite. These boundaries are recognized and identified when observing a cross section of the abrasive article with a scanning electron microscope. These boundaries separate and distinguish precisely shaped abrasive composites from each other, even when the composites are adjacent to each other along their boundaries at their bottom. By comparison, in a shaped abrasive composite that does not have a precise shape, the boundaries and edges are not well defined (eg, when the abrasive composite bends before curing is complete).

  The shaped abrasive composite can be arranged such that the workpiece is recessed by polishing the surface of the structured abrasive layer.

  Any abrasive particles can be included in the abrasive composite. Typically, the abrasive particles have a Mohs hardness of at least 8, and even 9. Examples of suitable abrasive particles include aluminum oxide, molten aluminum oxide, ceramic aluminum oxide, white molten aluminum oxide, heat treated aluminum oxide, silica, silicon carbide, green silicon carbide, silicon nitride, alumina zirconia, diamond, iron oxide, Examples include ceria, cubic boron nitride, garnet, tripoly, sol-gel abrasive particles, and combinations thereof.

  Typically, the abrasive particles have an average particle size of 1500 micrometers or less, but average particle sizes outside this range can also be used. In repair and finishing applications, useful abrasive particles range in average particle size ranging from at least 0.01, 1, 3, or 5 micrometers to 35, 100, 250, 500, or 1,500 micrometers or less.

  The abrasive particles are dispersed in the binder to form an abrasive composite. The binder may be a thermoplastic binder, but is typically a thermosetting binder. Examples of binders suitable for use in the abrasive composite include phenolic resin, aminoplast, urethane, epoxy, acrylic, cyanate, isocyanurate, glue, and combinations thereof. Typically, the binder will at least partially cure (polymerize) the corresponding binder precursor, usually in the presence of a suitable curing agent (eg, photoinitiator, thermal curing agent and / or catalyst). It is prepared with.

  The binder is formed from a binder precursor. During the manufacture of the structured abrasive article, the thermosetting binder precursor is exposed to an energy source that facilitates the initiation of the polymerization or curing process. Examples of energy sources include thermal energy and radiation energy including electron beam, ultraviolet light, and visible light.

  After this polymerization step, the binder precursor is converted into a solidified binder. Alternatively, in the thermoplastic binder precursor, during the manufacture of the abrasive article, the thermoplastic binder precursor is cooled to an extent that causes the binder precursor to solidify. During the solidification of the binder precursor, an abrasive composite is formed.

  There are two main types of thermosetting resins: condensation curable resins and addition polymerizable resins. Addition polymerizable resins are advantageous because they are easily exposed to radiation energy. The addition polymerizable resin can be polymerized by a cationic mechanism or a free radical mechanism. Depending on the energy source utilized and the properties of the binder precursor, curing agents, initiators or catalysts are often preferred to help initiate the polymerization.

  Examples of typical binder precursors include phenolic resins, urea formaldehyde resins, aminoplast resins, urethane resins, melamine formaldehyde resins, cyanate resins, isocyanurate resins, acrylate resins (eg, acrylated urethane, acrylated epoxy, ethylene). An unsaturated compound, an aminoplast derivative having a pendant α, β-unsaturated carbonyl group, an isocyanurate derivative having at least one pendant acrylate group, and an isocyanate derivative having at least one pendant acrylate group) vinyl ether, epoxy resin, and These mixtures and combinations may be mentioned. The term acrylate includes acrylates and methacrylates.

  Phenol resins are suitable for the present invention, have good thermal properties and effectiveness, are relatively low in cost, and are easy to handle. There are two types of phenolic resins, novolak and risol. Resole phenolic resins have a formaldehyde: phenol molar ratio of 1: 1 or greater and are typically in the range of 1.5: 1.0 to 3.0: 1.0. The novolak resin has a formaldehyde: phenol molar ratio of less than 1: 1. Examples of commercially available phenolic resins include the trade names "DUREZ" and "VARCUM" from Occidental Chemicals, Dallas, Texas; St. Louis, MO Known by Monsanto's “RESINOX”; and Ashland Specialty Chemical's “AEROFENE” and “AROTAP” in Dublin, Ohio Are listed.

  Acrylic urethanes are hydroxy-terminated NCO extended polyesters or diacrylate esters of polyethers. Commercially available acrylate urethanes include Morton Thiokol Chemical's trademark designation "UVITHANE 782" and UCB Radcure's trademark designation "CMD6600", "Mycna, Georgia" CMD8400 "and" CMD8805 ".

  Acrylated epoxies are diacrylate esters of epoxy resins, such as diacrylate esters of bisphenol A epoxy resins. Examples of commercially available acrylated epoxies include UCB Radcure's trademark designations “CMD 3500”, “CMD 3600” and “CMD 3700”.

  Ethylenically unsaturated resins include both monomers and polymer compounds containing carbon atoms, hydrogen atoms, and oxygen atoms, and optionally nitrogen atoms and halogens. Oxygen or nitrogen atoms or both are generally present in ether groups, ester groups, urethane groups, amide groups, and urea groups. The ethylenically unsaturated compound preferably has a molecular weight of less than 4,000 g / mol, preferably a compound containing an aliphatic monohydroxy group or an aliphatic polyhydroxy group, and acrylic acid, methacrylic acid, itaconic acid , Esters produced from reaction with unsaturated carboxylic acids such as crotonic acid, isocrotonic acid, and maleic acid. Typical examples of acrylic resins include methyl methacrylate, ethyl methacrylate styrene, divinyl benzene, vinyl toluene, ethylene glycol diacrylate, ethylene glycol methacrylate, hexanediol diacrylate, triethylene glycol diacrylate, trimethylolpropane triacrylate, glycerol Examples include triacrylate, pentaerythritol triacrylate, pentaerythritol methacrylate, pentaerythritol tetraacrylate, and pentaerythritol tetraacrylate. Other ethylenically unsaturated resins include monoallyl, polyallyl, and polymethallyl esters, and amides of carboxylic acids such as diallyl phthalate, diallyl adipate, and N, N-diallyl adipamide. Still other suitable nitrogen-containing compounds include tris (2-acryloyl-oxyethyl) isocyanurate, 1,3,5-tri (2-methacryloxyethyl) -s-triazine, acrylamide, N-methylacrylamide, N, N-dimethylacrylamide, N-vinyl pyrrolidone, and N-vinyl piperidone are mentioned.

  The aminoplast resin has at least one pendant α, β unsaturated carbonyl group per molecule or oligomer. These unsaturated carbonyl groups may be acrylate, methacrylate, or acrylamide type groups. Examples of such materials include N- (hydroxymethyl) acrylamide, N, N'-oxydimethylenebisacrylamide, ortho and paraacrylamide methylated phenol, acrylamide methylated phenol novolac, and combinations thereof. These materials are further described in US Pat. Nos. 4,903,440 and 5,236,472 (both Kirk et al.).

  Isocyanurate derivatives having at least one pendant acrylate group and isocyanate derivatives having at least one pendant acrylate group are further described in US Pat. No. 4,652,274 (Boettcher et al.). An example of one isocyanurate is the triacrylate of tris (hydroxyethyl) isocyanurate.

  Epoxy resins have one or more epoxide groups that can be polymerized by ring opening of the epoxide groups. Such epoxide resins include monomeric epoxy resins and oligomeric epoxy resins. Examples of useful epoxy resins include 2,2-bis [4- (2,3-epoxypropoxy) -phenylpropane] (diglycidyl ether of bisphenol), and Shell Chemical of Houston, Texas. Trademark designations “EPON 828”, “EPON 1004”, and “EPON 1001F”; and the trademark designation “DER” of Dow Chemical, Midland, Michigan -331 "," DER-332 ", and" DER-334 ". Other suitable epoxy resins include glycidyl ethers of phenol formaldehyde novolaks marketed under the trade designations “DEN-431” and “DEN-428” from Dow Chemical.

  The epoxy resins of the present invention can be polymerized through a cationic mechanism with the addition of a suitable cationic curing agent. The cationic curing agent creates an acid source for initiating polymerization of the epoxy resin. Examples of these cationic curing agents include salts having onium cations and metal- or metalloid-halogen-containing complex anions.

  Other cationic curing agents include organometallic complex cations and halogen-containing salts containing metal or metalloid complex anions as further described in US Pat. No. 4,751,138 (Tumey et al.). Can be mentioned. Other examples are U.S. Pat. Nos. 4,985,340 (Palazzotto et al.); 5,086,086 (Brown-Wensley et al.); And 5,376,428. (Palazzotto et al.). In addition, other cationic curing agents include those of groups IVB, VB, VIB, VIIB and VIIIB of the periodic table described in US Pat. No. 5,385,954 (Palazzotto et al.). Examples include ionic salts of organometallic complexes in metals selected from elements.

  About free radical curable resin, it is preferable that polishing slurry contains a free radical hardening | curing agent depending on the case. However, in the case of an electron beam energy source, a curing agent is not always required because the electron beam itself produces free radicals.

  Free radical thermal initiators include, for example, peroxides such as benzoyl peroxide and azo compounds. Compounds that produce free radical sources when exposed to actinic radiation (electromagnetic radiation) are commonly referred to as photoinitiators. Examples of photoinitiators when exposed to ultraviolet radiation that produces free radical sources include organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acrylic halides, hydrazones, mercapto compounds, pyrylium compounds, Examples include, but are not limited to, those selected from acrylic imidazole, bisimidazole, chloroalkyltriazine, benzoin ether, benzyl ketal, thioxanthone, and acetophenone derivatives, and mixtures thereof. Examples of initiators that produce a free radical source when exposed to visible light can be found in US Pat. No. 4,735,632 (Oxman et al.). One photoinitiator suitable for use with visible light is available under the trade designation “IRGACURE 369” from Ciba Specialty Chemicals, Inc., Tarrytown, NY.

  In order to promote the bridging bond between the binder and abrasive particles described above, a silane coupling agent is typically included in the slurry of abrasive particles and binder precursor, typically in a 0.01 to 5 weight ratio, more typically. May be included in a 0.01-3 weight ratio, more typically 0.01-1 weight ratio, although other amounts may be used, for example, depending on the size of the abrasive particles. Suitable silane coupling agents include, for example, methacryloxypropylsilane, vinyltriethoxysilane, vinyltri (2-methoxyethoxy) silane, 3,4-epoxycyclohexylmethyltrimethoxysilane, γ-glycidoxypropyltri Methoxysilane, and γ-mercaptopropyltrimethoxysilane (eg, Witco's trademark designations “A-174”, “A-151”, “A-172”, “A-”, Greenwich, Conn. 186 "," A-187 "and" A-189 "(corresponding to each)), allyltriethoxysilane, diallyldichlorosilane, divinyldiethoxysilane, and m, p-styrylethyltrimethoxysilane (e.g., Pennsylvania) United Chemicals, Bristol Trademark designations “A0564”, “D4050”, “D6205”, and “S1588” (corresponding to each) of United Chemical Industries, dimethyldiethoxysilane, dihydroxydiphenylsilane, triethoxysilane, Trimethoxysilane, triethoxysilanol, 3- (2-aminoethylamino) propyltrimethoxysilane, methyltrimethoxysilane, vinyltriacetoxysilane, methyltriethoxysilane, tetraethylorthosilicate, tetramethylorthosilicate, ethyltriethoxysilane , Amyltriethoxysilane, ethyltrichlorosilane, amyltrichlorosilane, phenyltrichlorosilane, phenyltriethoxysilane, methyltrichlorosilane, methyldichloro Orchids, dimethyldichlorosilane, dimethyl diethoxy silane, and mixtures thereof.

  A structural abrasive particle suitable for embossing forms a slurry of solidifying or polymerizable precursors of abrasive grains and the binder resin described above (i.e., binder precursor), and the slurry and substrate (or if present) The optional adhesive layer) is contacted, and the binder precursor is at least partially cured (eg, exposed to an energy source) such that the resulting structured abrasive article has a plurality of shaped abrasive composites secured to a substrate. Can be prepared. Examples of energy sources include thermal energy and radiation energy (including electron beam, ultraviolet light, and visible light).

  In certain embodiments, the slurry of abrasive particles in the binder precursor is applied directly to a production tool having a precisely shaped void therein and contacts the substrate (or any adhesive layer, if present). Or it can be applied to the substrate and brought into contact with the production tool.

  In this embodiment, the slurry is then solidified (eg, at least partially cured) while typically present in the voids of the production tool.

  The production tool can be a belt, a sheet, a continuous sheet or web, a coating roll such as a rotogravure, a sleeve mounted on the coating roll, or a die. The production tool can be composed of metal (eg nickel), metal alloy, or plastic. Metal production tools can be made by any conventional technique such as, for example, engraving, bobbing, electroforming, or diamond turning.

  The thermoplastic tool can be replicated from a metal master tool. The master tool will have a pattern opposite to that desired for a production tool. The master tool can be created in the same way as the production tool. The master tool is preferably made from a metal such as nickel and is diamond turned. The thermoplastic sheet material can be heated and optionally aligned with the master tool such that the two are pressed together to emboss the thermoplastic material in the pattern of the master tool. The thermoplastic resin can also be extruded onto a master tool and then pressurized. The thermoplastic material is consolidated and cooled until a production tool is produced. Examples of preferred thermoplastic production tool materials include polyester, polycarbonate, polyvinyl chloride, polypropylene, polyethylene and combinations thereof. When a thermoplastic production tool is used, care should be taken not to produce excessive heat that can deform the thermoplastic production tool.

  The production tool may also contain a release coating that allows the abrasive article to be easily separated from the production tool. Examples of such release coatings on metals include hard carbide, nitride or boride coatings. Examples of release coatings in thermoplastic resins include silicon and fluorochemicals.

  For further details regarding methods of manufacturing structured abrasive articles having precision shaped abrasive composites, see, for example, US Pat. Nos. 5,152,917 (Pieper et al.); (Spurgeon et al.); 5,672,097 (Hoopman et al.); 5,681,217 (Hoopman et al.); 5,454,844 (Hibbard et al.) No. 5,851,247 (Stoetzel et al.); And 6,139,594 (Kincaid et al.).

  The precisely shaped abrasive composite may have any three-dimensional shape, which results in at least one of a raised shape or recess on the exposed surface of the abrasive layer. Examples of useful shapes include a cubic shape, a prism shape, a pyramid shape (for example, a quadrangular pyramid shape or a hexagonal pyramid shape), a truncated pyramid shape, a frustum shape, and a truncated cone shape. Combinations of abrasive composites of different shapes and / or sizes may also be used.

  In other embodiments, a slurry comprising a binder precursor and abrasive particles is deposited on a substrate in a patterning method (eg, screen or gravure printing) and is at least a coated slurry plastic that does not flow. It can partially polymerize for rendering. Next, a pattern is formed on the partially polymerized slurry formulation that is substantially further cured (eg, exposed to an energy source) to form a shaped abrasive composite that is secured to a substrate. Embossed. Further details regarding this method and related methods are described, for example, in U.S. Pat. Nos. 5,833,724 (Wei et al.); 5,863,306 (Wei et al.); 476 (Nishio et al.); 6,048,375 (Yang et al.); 6,293,980 (Wei et al.); And US Patent Application Publication No. 2001/0041511 (Lack et al.).

  In precision finishing applications, the height of the shaped abrasive composite is generally greater than or equal to 1 micrometer and less than or equal to 510 micrometers (20 mils); for example, less than 380 micrometers (15 mils), Less than 200 micrometers (10 mils), 200 micrometers (5 mils), 5 micrometers (2 mils), or even less than 25 micrometers (1 mil), higher and lower heights may be used.

  In precision finishing applications, the surface density of the shaped abrasive composite in the polishing layer is typically shaped polishing, for example in the range of at least 150, 1,500, or even 7,800 per square centimeter. A composite (shaped abrasive composite of at least 50,000 or less, 70,000 or less, or even 100,000 or less per square inch), 7,800, 11,000, or even 15,000 per square centimeter Although less than 000 shaped abrasive composites, higher or lower shaped abrasive composite densities may also be used.

  Once the structured abrasive layer is secured to the substrate, the resulting structured abrasive article, whether it is a sheet or a disk at this point, has an overlapping embossing feature. Embossing includes, for example, applying heat and / or pressure to an embossing die (ie, by embossing) having a desired pattern (or reverse pattern) depending on the embossing conditions used. Can be achieved by any suitable means. The embossing die can include, for example, a plate or a roll. Typically, the dimensions of the embossing features will be at least an order of magnitude greater (eg, at least 10, 100, or even at least 1000 times) in cross-section than the average dimension of the shaped abrasive composite. The embossing features can have any shape or combination of shapes, or can be arranged according to a pseudo-random or standard pattern. For example, they can include dimples, posts, ridges, letters, geometric shapes, graphic designs, and combinations thereof. The embossing feature can be truncated or gradual. In certain embodiments, the density of embossed features can be at least 1, 2, 5, 10 or more per square centimeter.

  Generally, for the entire area of the substrate or any adhesive layer that contacts the structured polishing layer, 5 to 95 percent of the structured polishing layer is included within the embossing features of the substrate, but at higher and lower percentages. Can also be used. Typically, it is desirable to adjust the percent content to obtain high grinding cut values while maintaining low static friction.

  The embossed structure abrasive article according to the present invention can be fixed to the support structure, for example, on a backup pad fixed to a tool such as a random orbital sander. The optional attached boundary layer can be an adhesive (eg, pressure sensitive adhesive) layer or a double-sided adhesive tape. Any attached boundary layer may be configured to work with one or more complementary elements that are secured to a support pad or backup pad in order to function properly. For example, any attached boundary layer can be a loop configuration in a hook and loop appendage (eg, used for a backup or support pad to which the hook structure is secured), a hook structure in a hook and loop appendage (eg, a loop configuration is Or a mating appendage boundary layer (eg, a mushroom interlocking fastener designed to mate with a similar mushroom interlocking fastener on the backup or support pad). Further details regarding such attached boundary layers can be found, for example, in U.S. Pat. Nos. 4,609,581 (Ott), 5,152,917 (Pieper et al.), 5,254,194. (Ott), 5,454,844 (Hibbard et al.), 5,672,097 (Hoopman), 5,681,217 (Hoopman, et al.) ), U.S. Patent Application Publication Nos. 2003/0143938 (Braunschweig et al.) And 2003/0022604 (Annen et al.).

  Similarly, the second major surface of the substrate has a plurality of protrusions formed integrally, as described, for example, in US Pat. No. 5,672,186 (Chesley et al.). Can do. In doing so, these hooks will fit between the structured abrasive article and a backup pad with a fixed loop configuration.

  The embossed structured abrasive article according to the present invention can be provided in any form (eg, sheet, belt, or disk) and can be of any overall size. The embossed structured abrasive disc can have any diameter, but typically has a diameter in the range of 0.5 centimeters to 15.2 centimeters.

  The embossed structured abrasive article may have slots or slits therein or may be provided with perforations.

  The embossed structured abrasive article according to the present invention is generally useful for polishing workpieces, particularly workpieces having a reinforced polymer layer.

  The workpiece may include any material and may have any form. Examples of materials include metals, metal alloys, exotic metal alloys, ceramics, painted surfaces, plastics, polymer coatings, stones, polycrystalline silicon, wood, marble, and combinations thereof. Examples of workpieces include molded and shaped articles (eg, optical lenses, body panels, hulls, counters, and sinks), wafers, sheets, blocks.

  Embossed structured abrasive articles according to the present invention are typically useful for repairing and / or polishing polymer coatings such as automotive paints and clearcoats (eg automotive clearcoats), for example polyacrylic Acid-polyol-polyisocyanate compositions (eg, as described in US Pat. No. 5,286,782 (Lamb et al.)); Acrylic acid-polyol-polyisocyanate compositions having hydroxy groups (eg, US Patent 5,354,797 (Anderson et al.); Polyisocyanate-carbonate-melamine compositions (eg, US Pat. No. 6,544,593 (Nagata et al.)); And high solid polysiloxane compositions Product (eg, US Pat. No. 6,428,898 (Barsotti et al.)). And the like.

  A protective gloss finish, such as in an automobile, typically arises from a clearcoat layer applied over a colored basecoat. This applied clear coat finish always includes a texture commonly referred to as “orange peel”. In the process of polishing away defects (eg, dust nibs) in the clearcoat, orange peel in the area to be polished is generally improved. Depending on the specific environment and texture of the orange peel in the surrounding area, it may be desirable to remove (planarize) most or all of the orange peel texture. In other examples, it may be desirable to leave as much orange peel texture as possible, also known as “riding” on the orange peel.

In an embossed structured abrasive article according to the present invention comprising a fine grain abrasive (eg, P500 or less), the ability to flatten or ride orange peel can be controlled by selecting an appropriate substrate. On the other hand, a relatively hard and incompressible substrate such as, for example, a polyester film or paper will typically result in an abrasive article that tends to smooth the orange peel. On the other hand, relatively soft substrates (eg, elastic foam) tend to ride on orange peel, thereby leaving more texture after polishing. When removing dust nibs with a new clear coat applied to the car, it is usually desirable to substantially remove the nibs while removing as much orange peel texture as possible. Typically, the properties between these two counter electrodes are continuous so that a suitable substrate can be found that provides an aesthetically acceptable balance between the two. For example, in a new automotive clearcoat denibing, a hardness between the hardness of the polyester film and the hardness of 100 kg / m ³ (6 lb / ft ³ ) polyurethane foam that is continuous foam (eg, Shore A, B, C or D A substrate having a hardness) is typically preferred. The thickness of the substrate also typically affects the ability of the embossed structured abrasive article to smooth orange peel. For example, as the substrate becomes thicker, the ability of the abrasive to conform locally to the orange peel decreases.

  Depending on the application, the force at the polishing boundary can vary from 0.1 kg to over 1000 kg. Generally, this range is between 1 kg and 500 kg of force at the polishing boundary. Also, depending on the application, liquid may be present during polishing. This liquid may be water and / or an organic compound. Typically, examples of organic compounds include lubricants, oils, emulsified organic compounds, cutting fluids, surfactants (eg, soaps, organic sulfuric acids, sulfonic acids, organic phosphonic acids, organic phosphoric acids), and combinations thereof Is mentioned. These liquids may also contain other additives such as antifoams, degreasing agents, corrosion inhibitors, and combinations thereof.

  The embossed structured abrasive article according to the present invention is used with, for example, a rotating tool that rotates a central axis that is generally perpendicular to the structured abrasive layer, or a random orbit (eg, a random orbital sander), and at the abrasive boundary during use. Can vibrate. In some cases, this vibration can result in a finer surface on the workpiece being polished.

  The objects and advantages of this invention are further illustrated by the following non-limiting examples, which illustrate the specific materials and amounts thereof, as well as other conditions and details, cited in these examples. It should not be construed as limiting.

  Unless otherwise specified, all parts, percentages, ratios, etc. in the examples and the remainder of the specification are by weight, and all reagents used in the examples are, for example, Saint Louis, Missouri. ) From general chemical suppliers such as Sigma-Aldrich Company, or may be synthesized by conventional methods.

The following abbreviations are used throughout the examples.
MN1: JIS 1000 series silicon carbide polishing mineral marketed under the trademark designation “GC1000” of Fujimi Corp. of Elmhurst, Illinois.
MN2: A JIS 2000 series silicon carbide polishing mineral marketed under the trademark designation “GC2000” of Fujimi Corp. of Elmhurst, Illinois.
PM1: 2-phenoxyethyl acrylate monomer available under the trade designation “SR339” from Sartomer, Exton, Pa.
PM2: Trimethylolpropane triacrylate available under the trade designation “SR351” from Sartomer.
PM3: A polymeric dispersant available under the trade designation "SOLPLUS D520" from Noveon, Cleveland, Ohio.
PM4: A γ-methacryloxypropyltrimethoxysilane resin modifier available under the trade designation “SILQUEST A174” of Witco, Greenwich, Connecticut.
PM5: Ethyl 2,4,6-trimethylbenzoylphenyl phosphinate photoinitiator available under the trade designation “LUCIRIN TPO-L” from BASF Corporation of Charlotte, NC.
PM6: silicon dioxide available under the trade designation “AEROSIL OX-50” from Degussa, Dusseldorf, Germany.

Preparation of Abrasive Slurry 1 (AS1) PM1 (146.5 grams), 146.5 grams PM2, 41.85 grams PM3, 31.41 grams PM4 and 331.41 grams PM5 at 20 ° C. for 10 minutes. Synthesized and mixed. While continuing to mix until the mixture appeared uniform, PM6 (52.29 grams) was added to the mixture to produce a resin premix. MN1 (596 grams) was added to 450 grams of the resin premix and the mixture was mixed for 5 minutes in a high speed shear mixer until a homogenate gave the abrasive slurry AS1. The temperature during the high speed mixing process was maintained below 37.8 ° C. (100 ° F.).

Comparative Example A
U.S. Pat. No. 6,923,840 (Schutz et al.), Column 14, 22-41, and polypropylene product with a uniform pattern, as disclosed in FIGS. 13-15, with knife coating. AS1 was applied. Adhesion of polypropylene film coated with 178 micrometer (7 mil) thick adhesive, which is commercially available as a 3M brand trademark "3M481 PRESERVATION TAPE" The drug surface was brought into contact. Next, the production tool was obtained from Fusion Systems, Gaithersburg, Maryland, moving the web at a speed of 9.14 meters / minute (30 feet / minute) Ultraviolet light (UV) of the “D” bulb type operating at 236 watts / cm (600 watts / inch) using a nip pressure of 410 kilopascals (kPa) (60 lbs / in 2) at 10 inches The lamp was irradiated. The production tool was separated from the substantially cured shaped abrasive coating.

Comparative Example B
“3M481 PRESERVATION TAPE” by transporting the tape through a set of chrome steel nip rolls and using a nip pressure of 48.2 kN / m (275 pounds per inch of web width) for the web width The dimples were heat embossed. One of the nip rolls is 20 ° C. and the other roll is patterned with 1.0 mm (diameter) and 2.3 mm high protrusions that are uniformly distributed on the roll surface and occupy 20% of the area. Heat to 93.3 ° C. (200 ° F.). Next, AS1 was applied to the adhesive side of the dimpled polyethylene substrate according to the method described in Comparative Example A.

Comparative Example C
Dimples so that 47% of the roll surface, evenly distributed on the roll surface, is occupied by holes and the nip pressure is 43.8 kN / m of web width (250 pounds per linear inch of web width) A structured abrasive article was prepared according to the method described in Comparative Example B, except that the modified nip roll was replaced with a patterned roll containing 3.25 mm (diameter) holes.

(Example 1)
An embossed structure abrasive article was prepared according to the method described in Comparative Example B except that the polyethylene substrate was embossed after application and curing of the abrasive slurry.

(Example 2)
An embossed structured abrasive article was prepared according to the method described in Comparative Example C, except that the polyethylene substrate was embossed after application and curing of the abrasive slurry.

  The structural abrasive discs of Comparative Examples A-C and Examples 1 and 2 are as described in US Pat. No. 6,923,840 (Schutz et al.), Column 15, line 62 to column 16, line 7. Laminated on an adhesive coated flat surface of a polypropylene mechanical fastener laminate with hook stems on opposite surfaces. A 15.2 cm (6 inch) disc was then die cut from the sheet materials of Comparative Examples A-C and Examples 1 and 2.

Test The cutting and finishing performance of the abrasive discs was tested in an automotive clearcoat. Furthermore, a qualitative assessment was made of whether the abrasive produces any “serious scratches” in static friction when wet operating each abrasive during polishing and during the polishing process. The work piece is a 45.7 cm x 61 cm (18 inch x 24 inch) clear coated black painted cold rolled steel sheet test panel, a trademark of ACT Laboratories, Hillsdale, Michigan. Obtained as the notation “APR45077”. Next, commercially available from 3M to be attached to a random orbit sander of model number “59025” obtained from Dynabrade of Clarence, NY to ensure mechanical paint adhesion The panel was rubbed at a line pressure of 276 kilopascals (kPa) (40 pounds per square inch) using a "TRIZACT HOOKIT II BLENDING DISC 443SA, P1000 grade". First, the periphery of the panel was ground, and then the panel was rubbed by polishing the entire panel by up and down movement and left and right movement. When this process was completed, the panel had a matte finish. The panel was wiped with a dry paper towel to remove wet shavings.

  All from E. Wilmington, Delaware. 3 parts of resin available under the trade designation “CHROMA CLEAR G24500S”, available from du Pont de Nemours & Co, available under the trade designation “62-4508S” A clear coat solution was prepared by mixing together 1 part of an active agent and 1 part of a reducing agent available under the trade designation “12375S”. 1.3 mm spray nozzle spray used at 276 kPa (40 pounds per square inch), the “RP” type of SATA Farbspritztechnik limited liability company in Kornwestheim, Germany A clear coat was applied to the panel using a gun. The clearcoat solution was sprayed onto each panel at a nominal thickness of 51 micrometers (2 mils). Prior to use, the panel is dried by air at room temperature for 3 days, which is hereinafter referred to as workpiece WP1.

Each test panel was divided into 4 lanes, 45.7 cm (18 inches) long, with each lane being 15.2 cm (6 inches) wide. Each abrasive disc was tested by wet polishing (using water) for 30 seconds per lane. The test panel was weighed before polishing each lane. The difference in mass is the measured cut and is reported as grams per 30 seconds. After polishing, the average surface finish (R _z ) in micrometer (μm) of each lane is the trademark designation “SURTRONIC 3+ PROFILOMETER” of Taylor Hobson of Leicester, UK ”Using a surface meter available as R _z is an average of five measurements for the difference in the vertical direction between the highest point and the lowest point of the sample length in each surface gauge measurement value. Five finishing measurements were performed per lane. Four abrasive discs were tested per lot so that the reported cut was an average of 4 measurements and the reported finish was an average of 20 measurements, and the average of all 4 abrasive discs Asked.

  The “static friction”, ie the tendency of the abrasive coating to stick to the workpiece surface, was also commented with unnecessary results. Generally, in precision finishing applications, it is desirable to minimize static friction. After finishing measurements on each panel, the presence of “serious scratches” was visually inspected. “Severe scratches” are deep scratch lines that are spiral or hook-like in the direction in which the DA sander moves over the abrasive substrate. To test “serious scratches”, the panel was rotated 1400 rpm using a Dewalt Buffer model number 849 commercially available from Dewalt Industrial Tool, Hampstead, Maryland. Buffing was performed by operating every minute (rpm). Machine glaze available under the trademark notation "PERFECT-IT III TRIZACT MACHINE GLAZE part number 05930", trademark notation "HOOK-IT BACKUP PAD part number 05718" And a polishing pad available under the trade designation “PERFECT-IT FOAM POLISHING PAD Part No. 05995”, all commercially available from 3M. The buffing process in this case is intended to remove most of the scratches. The panel was then visually inspected for “serious scratches”. In general, it is desirable to minimize the generation of “serious scratches”. The results are shown in Table 1 (below).

Preparation of Abrasive Slurry 2 (AS2) AS2 was also prepared using the resin premix used in AS1. MN2 (596 grams) was added to 450 grams of the resin premix and the mixture was mixed for 5 minutes in a high speed shear mixer until the homogenous gave abrasive slurry AS2. The temperature during the high speed mixing process was maintained below 37.8 ° C. (100 ° F.).

(Example 3)
A structured abrasive film was prepared according to the method described in Comparative Example A, except that AS1 was replaced with AS2. Subsequently, the resulting structured abrasive film was embossed using the patterns and conditions described in the comparative examples.

(Example 4)
A structured abrasive film according to the method described in Example 3, except replacing "3M481 PRESERVATION TAPE" with a 94.2 micrometer (3.71 mil) polyester film sold as "MA370M" from 3M. Was prepared.

(Example 5)
A structured abrasive film was prepared according to the method described in Example 4 except that the polyester film was replaced with a 400 micrometer (16 mil) thick elastic tape available as 3492 “4921 tape”.

(Example 6)
A structured abrasive film was prepared according to the method described in Example 4 except that the polyester film was replaced with a 50 micrometer (2 mil) polypropylene tape commercially available from 3M and available as “375 tape”.

  The embossed structure polishing sheets of Examples 3 to 6 were respectively laminated on double-sided adhesive films sold as “442 KW” tapes from 3M Company. Disks (1.5 inches in diameter) were die cut from the sheet material and evaluated.

  A WP1 workpiece was used to test the effectiveness of the abrasive substrate in improving orange peel texture.

  In each of Examples 3-6, a 3.8 cm disc (1.5 inch) was used to polish the two dust nibs in the panel. All samples were tested in a single WP1 panel for convenient relative comparison of texture improvements. Each structured abrasive disc operates at a line pressure of 280 kilopascals (kPa) (40 pounds per square inch) using a backup pad part number 02345 commercially available from 3M Company, Clarence, NY It was attached to a random orbit sander model number “57002” obtained from Dynabrade. Each dust nib was dry polished for 5 seconds. The polished area was then buffed using a Dewalt model 849 buffer, commercially available from Dewalt Industrial Tool, operating at 1400 revolutions per minute (rpm). Machine glaze available under the trademark notation "PERFECT-IT III TRIZACT MACHINE GLAZE part number 05930", trademark notation "HOOK-IT BACKUP PAD part number 05718" And a polishing pad available under the trade designation “PERFECT-IT FOAM POLISHING PAD Part No. 05995”, all commercially available from 3M. The polished and buffed WP1 panels were then visually inspected to qualitatively evaluate the extent of both nib removal and orange peel texture improvement.

Orange peel rating scale:
1 = No change in appearance of orange peel 2 = Slight change in orange peel texture 3 = Orange peel texture was reduced, but remaining orange peel texture was also mixed 4 = In the detailed inspection, orange peel was significantly reduced 5 = significantly flattened significantly in orange peel texture

Nib removal rating scale:
1 = No change in the appearance or dimensions of the nibs 2 = roundness around the nibs 3 = significant reduction in the nib dimensions but mixed orange peel residue 4 = substantially removed nibs 5 = nib completely flattened

  The results are reported in Table 2 (below).

  Various modifications and alterations of this invention may be made by those skilled in the art without departing from the scope and spirit of this invention, but this invention is unnecessarily limited to the illustrative embodiments detailed herein. It should be understood that not.

1 is a schematic side view of an exemplary embossed structured abrasive article according to one embodiment of the present invention. FIG. The enlarged view of the grinding | polishing layer 130 part. 1 is a schematic side view of an exemplary embossed structured abrasive article according to one embodiment of the present invention. FIG. 1 is a schematic perspective view of an exemplary embossed structured abrasive article according to one embodiment of the present invention. FIG. 2 is a schematic perspective view of another embossed structured abrasive article according to one embodiment of the invention. FIG. FIG. 6 is a schematic perspective view of yet another embossed structured abrasive article according to one embodiment of the present invention.

Claims (21)

A substrate having first and second major surfaces and comprising an inelastic high density thermoplastic film;
An optional adhesive layer that contacts the first major surface, has the same extent and is fixed;
A structural polishing layer that contacts, is coextensive and fixed, in contact with the first major surface of the substrate or an optional adhesive layer, wherein the structural polishing layer includes abrasive particles and a binder and protrudes outward. The structural polishing layer comprising a precisely shaped polishing composite, wherein both the substrate and the structural polishing layer have a superposed embossed configuration,
An embossed structured abrasive article comprising an optional attached boundary layer secured to the second major surface,
The embossed structured abrasive article does not include a porous elastic element.   The embossed structure abrasive article according to claim 1, wherein the optional adhesive layer is present.   The embossed structured abrasive article of claim 1, wherein the optional attached boundary layer is present.   2. The embossed configuration of the substrate of claim 1, wherein 5 to 95 percent of the structured polishing layer is included within the embossed configuration of the substrate, relative to the entire area of the substrate or any adhesive layer that contacts the structured polishing layer. Embossed structure abrasive article.   The embossed structure abrasive article according to claim 1, wherein the second main surface is flat.   The embossed structure abrasive article of claim 1, wherein the precisely shaped abrasive composites are substantially identical.   The embossed structure abrasive article according to claim 1, wherein the embossed configuration includes dimples.   The embossed structured abrasive article of claim 1, wherein the embossed configuration comprises a post.   The embossed structure abrasive article according to claim 1, wherein the abrasive particles have an average dimension in a range of at least 0.01 to 1,500 micrometers or less.   The embossed structured abrasive article of claim 1, wherein the abrasive composite has an abrasive composite that has been processed to a surface density in the range of at least 150 to 15,000 or less per square centimeter of the structured abrasive layer.   The embossed structured abrasive article of claim 1, wherein the structured abrasive article comprises a structured abrasive disc.   The embossed structured abrasive article of claim 11, wherein the disk has a diameter in the range of 0.6 centimeters to 15.2 centimeters. a) providing an embossed structured abrasive article according to claim 1;
b) providing a workpiece having a reinforced polymer layer thereon;
c) frictionally contacting at least a portion of the structured polishing layer with the polymer layer;
d) moving at least one of the workpiece and the structured polishing layer relative to the other to polish at least a portion of the polymer layer.   The method of claim 13, further comprising contacting a liquid with at least a portion of the polymer layer and at least a portion of the structured polishing layer during step (d).   The method of claim 13, wherein the polymer layer comprises an automotive clearcoat. Providing a substrate having first and second major surfaces and comprising an inelastic high-density thermoplastic film;
Contacting the first main surface and fixing the adhesive layer to have the same extent;
A step of fixing the structural polishing layer so as to be in contact with the adhesive layer and to have the same spread, wherein the structural polishing layer includes abrasive particles and a binder and is precision-shaped so as to protrude outwardly; A fixing step comprising a polishing composite comprising:
In the base material and the structural polishing layer, embossing the base material and the structural polishing layer, and providing a superposed emboss shape configuration;
Optionally fixing a mounting boundary layer to the second main surface,
Thereby, the manufacturing method of an embossed structure abrasive | polishing article which provides the embossed structure abrasive | polishing article which does not contain a porous elastic element.   The method of claim 16, further comprising converting the structured abrasive article to at least one structured abrasive disc.   17. The method of claim 16, wherein 5 to 95 percent of the structured polishing layer is included in the embossed configuration of the substrate, relative to the entire area of the substrate or any adhesive layer that contacts the structured polishing layer. . Providing an inelastic high density thermoplastic film substrate having first and second major surfaces;
A step of fixing the structural polishing layer to the substrate, wherein the structural polishing layer is in contact with the adhesive layer, has the same spread, includes abrasive particles and a binder, and has a precise shape so as to protrude outward A process composed of a structured abrasive composite;
In the base material and the structural polishing layer, embossing the base material and the structural polishing layer, and providing a superposed emboss shape configuration;
Optionally fixing a mounting boundary layer to the second main surface,
Thereby, the manufacturing method of an embossed structure abrasive | polishing article which provides the embossed structure abrasive | polishing article which does not contain a porous elastic element.   The method of claim 19, further comprising converting the structured abrasive article into at least one structured abrasive disc.   20. The method of claim 19, wherein 5 to 95 percent of the structured polishing layer is included in the embossed configuration of the substrate relative to the entire area of the substrate or any adhesive layer that contacts the structured polishing layer. .

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