KR20160088920A - Coated abrasive article including a non-woven material - Google Patents

Abstract

The coated abrasive article comprises a body and the body comprises a support comprising a saturant contained in a spunlaced polyester based material and a spunlaced polyester based material and an abrasive layer disposed on the support and comprising abrasive particles, , The saturating agent comprises a material selected from the group consisting of phenolic resin, acrylic, urea resin, and combinations thereof.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a coated abrasive article comprising a non-

The present invention relates generally to a coated abrasive article, and more particularly to a coated abrasive article comprising a nonwoven material.

Abrasive articles, such as fixed, coated, and bonded abrasive articles, are applied to a variety of industries for workpiece polishing or machining, e.g., by lapping, grinding, or polishing. Machining using abrasive articles covers a wide range of industries, from optics, automotive sheet metal painting and welding to construction and woodworking. Machining by means of commonly used tools such as a combination automated system or by hand or by means of commonly available tools such as, for example, orbital polishers (both random and fixed axes) and belts and vibrating sanders, To achieve desirable surface properties.

Surface properties include, among other things, gloss, texture, gloss, surface roughness and uniformity. In particular, surface properties such as roughness, gloss, and surface imperfections are applied to quality determination. For example, when applying or painting a surface, certain defects or surface defects are generated during the application or curing process. Such surface defects or surface defects include entangled marks, " orange fill " textures, " silver spots ", or dust defects, also known as encapsulated bubbles and "dust nips. &Quot; Typically, these defects on the coating surface are first removed by grinding with a crude particle abrasive, followed by grinding with a finer particle abrasive, and even by buffer grinding with a wool or foam pad until smoothness is achieved. Thus, the properties of the abrasive articles used comprehensively affect the surface quality.

In addition to the surface properties, the industry is also sensitive to abrasive machining costs. Factors that affect the processing cost include the surface treatment rate and the material cost used for such surface treatment. Typically, the industry wants a cost-effective material with a high grinding rate.

However, abrasives exhibiting high grinding ratios are sometimes poor in achieving desirable surface properties. Conversely, abrasives that can achieve desirable surface properties often exhibit low grinding rates. For this reason, surface treatment often consists of multi-step operations using abrasive sheets of various grades. Typically, surface defects (e.g., scratches) that occur in one step are repaired (e. G., Removed) with finer particle abrasives in one or more subsequent steps. Thus, the abrasive that generates scratches and surface defects requires time, effort, and consumes material in subsequent processing steps, resulting in a high overall processing cost.

Another factor affecting the grinding rate and surface quality is that the workpiece surface is ground so that " swabs " that can accumulate on and between the surfaces of the abrasive particles are "loaded" onto the abrasive article. The loading phenomenon is typically undesirable because it lowers the abrasive product efficiency and may also adversely affect surface properties by increasing the probability of scratch defects.

The surface properties and the material grinding rate are also influenced by the abrasive article durability. Abrasive articles that are easily worn or lose their grain exhibit low material grinding rates and surface defects. If the abrasive article is worn out quickly, the material abrasion rate will be lowered, and the abrasive article will have to be replaced frequently, resulting in the abrasive article being discarded and wasted.

There is a need for improved abrasive articles.

The coated abrasive article comprises a body and the body comprises a material selected from the group consisting of a phenolic resin, acrylic, urea resin, and combinations thereof, contained in a spunlace polyester material and a spunlace polyester material And a polishing layer comprising abrasive particles overlying the support. ≪ Desc / Clms Page number 5 >

In another embodiment, the coated abrasive article comprises a body, wherein the body is a spunlaced polyester based material having an areal density of at least about 50 grams per square meter (GSM) and less than about 300 grams per square meter (GSM) And a saturant contained in a spunlaced polyester material, and an abrasive layer on the support and including abrasive particles.

In another aspect, a coated abrasive article includes a body, the body having a machine-directional stiffness of at least about 80 MPa and not more than about 220 MPa, and a cross-directional stiffness of at least about 1 MPa and not greater than about 40 MPa, A support further comprising a saturant contained within the nonwoven material, and an abrasive layer disposed on the support and comprising abrasive particles.

In yet another embodiment, a method of forming a coated abrasive article includes forming a support preform comprising a spunlaced polyester based material by saturating with a saturant containing a material selected from the group consisting of phenolic resin, acrylic, and combinations thereof, , And forming an abrasive layer overlying the support.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention may be better understood by reference to the accompanying drawings, and numerous features and advantages thereof may become apparent to those skilled in the art.

1 is a partial cross-sectional view of a coated abrasive article according to an embodiment.
2 is a partial cross-sectional view of a coated abrasive article according to an embodiment.
3 is a partial cross-sectional view of a coated abrasive article according to an embodiment.
4 is a partial cross-sectional view of a coated abrasive article according to an embodiment.
5 is a partial cross-sectional view of a conventional coated abrasive article.
6 shows a material removal amount and a material grinding rate chart of the coated abrasive article of the embodiments of the present embodiment as compared with, for example, a conventional product.
Figure 7 illustrates a dispensing system for a coated abrasive article according to an embodiment.
8 is a partial cross-sectional view of a coated abrasive article according to an embodiment.
In the different drawings, the same reference numerals denote the same or similar parts.

The following description, together with the drawings, is provided to assist in understanding the present invention. The following discussion will focus on particular implementations and embodiments of the present teachings. Such concentration is provided to describe the present teachings and should not be construed as limiting the scope or applicability of the present teachings.

The term " average " means a mean, a geometric mean, or an intermediate value when representing a value.

As used herein, the terms "comprises", "comprising", "includes", "including", "has", "having" Any other variation of these is intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features need not necessarily be limited to such features, It should be understood that the phrase "or" is used in an inclusive sense to refer to a "or" in an inclusive sense, For example, condition A or B is satisfied by any of the following: A is true (or exists), B is false (or does not exist), and A False (or nonexistent) B is True (or present), and both A and B are true (or exist).

"A" or "an" is used to describe the elements and components described herein. This is done merely for convenience and to give the general meaning of the scope of the present invention. This description should be read to include one or at least one, and the singular also includes the plural unless the context clearly dictates otherwise.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods and embodiments are illustrative only and not limiting.

The following generally relates to abrasive articles, and more particularly to a coated abrasive article comprising a body, which has a support and an abrasive layer overlying the support. In a particular example, the abrasive layer comprises abrasive particles contained in a single layer of abrasive material, e.g., one or more layers of adhesive material. Coated abrasive articles may be useful for material removal operations in a variety of industries including, but not limited to, automotive, woodworking, building and construction industries, new material finishes, and the like.

1 is a sectional view of a coated abrasive article according to an embodiment; As shown, the coated abrasive article 100 includes a body 101. The body 101 includes a support 102 which includes an upper major surface 104 and a lower major surface 103 on the opposite side of the upper major surface 104. The body 101 also includes an abrasive layer 107 overlying the support 102 and, more particularly, overlying the upper major surface 104 of the support 102. The abrasive layer 107 includes abrasive particles 109 and at least one adhesive layer 108 that connects and bonds the abrasive particles 109 to the support 102.

According to an embodiment, the support 102 comprises a nonwoven material. In particular, the nonwoven material is a spun lace material, which is a material formed through a hydroentanglement process. In at least one embodiment, the support 102 comprises a nonwoven material comprising a spunlaced polyester-based material. According to an embodiment, the spunlaced polyester-based material of the support 102 comprises mostly polyester on a volume basis. For example, the spunlaced polyester-based material comprises at least about 51 vol% polyester relative to the total volume of the support 102, and more specifically about the total volume of the nonwoven material. In more specific examples, the spunlaced polyester based material comprises at least 75 vol% polyester based on the total volume of the spunlaced polyester based material. For example, the spunlaced polyester-based material may be a composite comprising polyester and another polymer or inorganic material, and at least 75 vol% of the composite spunlaced material is a polyester. In another embodiment, the spunlaced polyester base material is substantially comprised of polyester, and more particularly, substantially of spunlaced polyester.

According to an embodiment, the nonwoven material of the support (e.g., a spunlaced polyester based material) has a specific surface density that realizes the formation of a coated abrasive article having features of the embodiments of the present disclosure. For example, the surface density of the nonwoven material, such as the spunlaced polyester material of the support 102, is at least 50 grams per square meter (i.e., g / m² or GSM). In yet another embodiment, the surface density of the nonwoven material, such as the spunlace polyester material of the support 102, is at least about 60 GSM, such as at least about 70 GSM, at least about 80 GSM, at least about 90 GSM, At least about 110 GSM, at least about 120 GSM, at least about 130 GSM, at least about 140 GSM, or at least about 150 GSM. In yet another embodiment, the surface density of the nonwoven material, such as the spunlaced polyester material of the support 102, is less than about 300 GSM, such as less than about 290 GSM, less than about 280 GSM, less than about 270 GSM, Or less, or about 250 GSM or less. It is to be understood that the face density of the support 102 nonwoven material, such as a spunlaced polyester based material, may be in the range between any of the minimum and maximum values.

According to another aspect, the nonwoven material (e.g., a spunlaced polyester material) of the support 102 has a specific thickness that realizes the formation of a coated abrasive article having the features of the embodiments of the present disclosure. For example, the average thickness of the nonwoven substrate may be about 10 mm or less, such as about 9 mm or less, about 8 mm or less, about 7 mm or less, about 6 mm or less, about 5 mm or less, about 4 mm or less, About 2 mm or less, about 1 mm or less, or about 0.95 mm or less. In another non-limiting embodiment, the average thickness of the support 102 nonwoven material is at least about 0.05 mm, such as at least about 0.08 mm, at least about 0.1 mm, at least about 0.2 mm, at least about 0.3 mm, at least about 0.5 mm, Or at least about 0.6 mm. It should be appreciated that the average thickness of the nonwoven material of the support can range between any of the minimum and maximum values.

According to an embodiment, the support 102 has a generally flat upper surface 104. In certain instances, the support 102 has a top surface 104 that is particularly smooth and realizes the formation of a coated abrasive article having the features of the embodiments. For example, the average surface roughness (Ra) of the top major surface 104 is less than about 20 占 퐉 (microns) when manually measured with a surface roughness gauge having a diamond needle commercially available from Mitutoyo Ltd. In other examples, the average surface roughness of the top major surface 104 is less than about 18 占 퐉, less than about 15 占 퐉, less than about 12 占 퐉, or less than about 10 占 퐉. In another non-limiting embodiment, the average surface roughness of the support 102 top surface 104 is at least about 1 占 퐉 or at least about 2 占 퐉. It should be appreciated that the average surface roughness of the top major surface 104 may be in the range between any of the minimum and maximum values.

According to another embodiment, the support 102 has a generally flat bottom surface 103. In particular, the lower major surface 103 has a specific smoothness for realizing the formation of a coated abrasive article having the features of the embodiments of the present invention. For example, in certain instances, the average surface roughness (Ra) of the lower major surface 103 is less than about 30 占 퐉 (microns) when manually measured with a surface roughness gauge having a diamond needle commercially available from Mitutoyo Ltd. In yet another example, the average surface roughness of the lower major surface 103 is less than about 30 占 퐉, less than about 25 占 퐉, less than about 22 占 퐉, less than about 20 占 퐉, less than about 18 占 퐉. In one non-limiting embodiment, the average surface roughness of the lower surface 103 of the support 102 is at least about 5 占 퐉, e.g., at least about 8 占 퐉. It should be appreciated that the average surface roughness of the lower major surface 103 of the support 102 may range between any of the minimum and maximum values.

As further shown, the support 102 is substantially a uniform, flat body. For example, in at least one embodiment, the support 102 has a generally flat, non-wrinkled contour. It should also be appreciated that although not shown in FIG. 1, the support 102 may take any suitable shape, contour, and dimensions. For example, in certain instances, the support 102 may be generally in the form of a rectangular sheet (top-down view). In still other embodiments, the support 102 may be in the form of a circular disc (top-down view). The coated abrasive article of embodiments herein may be in the form of a belt, a sheet, a disc, a nofil disc, and the like.

According to an embodiment, the support 102 has specific mechanical properties that enable the formation of a coated abrasive article having features of the embodiments of the present disclosure. For example, in at least one embodiment, the machine-directional stiffness of the support 102 comprising a nonwoven material and optional additives (e.g., a spunlaced polyester-based material and a saturant) is measured using a 2 kN load cell load cell of at least about 200 MPa when measured using an Instron 5982. The total sample length of the sample is 200 mm, the sample width is 25 mm, the gauge length is 127 mm, and the strain is tested at 300 mm / min. The modulus value is obtained from the stress-strain data. In yet another embodiment, the machine-directional stiffness of the support 102 is at least about 210 MPa, such as at least about 20 MPa, at least about 230 MPa, at least about 40 MPa, at least about 250 MPa, at least about 260 MPa, MPa, at least about 280 MPa, or at least about 290 MPa. In another non-limiting embodiment, the machine-directional stiffness of the support 102 is less than about 400 MPa, such as less than about 390 MPa, less than about 380 MPa, less than about 370 MPa, less than about 360 MPa, Or less. It should be appreciated that the machine-directional stiffness of the support 102 may be in the range between any of the minimum and maximum values.

In another embodiment, the cross-direction stiffness of the support 102 is at least about 1 MPa when measured using an Instron 5982 as a 2 kN load cell. The total sample length of the sample is 200 mm, the sample width is 25 mm, the gauge length is 127 mm, and the strain is tested at 300 mm / min. The elastic modulus values are obtained from the stress-strain data. In other examples, the cross-directional stiffness of the support 102 is at least about 2 MPa, at least about 3 MPa, at least about 4 MPa, at least about 5 MPa, at least about 6 MPa, at least about 7 MPa, at least about 8 MPa, It is about 10 MPa. In another non-limiting embodiment, the cross-directional stiffness of the support 102 is less than about 50 MPa, such as less than about 45 MPa, less than about 40 MPa, less than about 38 MPa, less than about 35 MPa, Or less. It should be appreciated that the cross-direction stiffness of the support 102 can range between any of the minimum and maximum values.

According to a particular embodiment, the support comprises a nonwoven material and comprises a spunlaced polyester based material as described herein. More specifically, the nonwoven material (e.g., a spunlaced polyester material) of the support 102 may have one or more specific mechanical properties that enable the formation of a coated abrasive article having any of the features of the embodiments herein . For example, in one embodiment, the machine-directional stiffness of a nonwoven material such as a spunlaced polyester based material is at least about 80 MPa when measured using an Instron 5982 as a 2 kN load cell. The total sample length of the sample is 200 mm, the sample width is 25 mm, the gauge length is 127 mm, and the strain is tested at 300 mm / min. The elastic modulus values are obtained from the stress-strain data. In yet another embodiment, the machine-directional stiffness of a nonwoven material such as a spunlaced polyester based material is at least about 80 MPa, such as at least about 90 MPa, at least about 100 MPa, at least about 110 MPa, 120 MPa. In another non-limiting embodiment, the machine-directional stiffness of the nonwoven material, such as the spunlaced polyester material of the support 102, is less than or equal to about 220 MPa, less than or equal to about 210 MPa, less than or equal to about 200 MPa, About 180 MPa or less, or about 160 MPa or less. It should be understood that the machine-directional stiffness of the nonwoven material, such as the spunlaced polyester material of the support 102, may be in the range between any of the minimum and maximum values.

According to another embodiment, the support 102 comprises a nonwoven material such as a spunlaced polyester-based material and has a specific cross-directional stiffness that implements the desired characteristics of the coated abrasive article. For example, in one embodiment, the cross-direction stiffness of the nonwoven material, such as a spunlaced polyester based material, is at least about 1 MPa when measured using an Instron 5982 as a 2 kN load cell. The total sample length of the sample is 200 mm, the sample width is 25 mm, the gauge length is 127 mm, and the strain is tested at 300 mm / min. The elastic modulus values are obtained from the stress-strain data. In another embodiment, the cross-directional stiffness of the nonwoven material, such as a spunlaced polyester based material, is at least about 2 MPa, such as at least about 3 MPa, at least about 5 MPa, or at least about 8 MPa. In yet another embodiment, the cross-directional stiffness of the nonwoven material, such as a spunlaced polyester material, is about 40 MPa or less, such as about 38 MPa or less, about 35 MPa or less, about 33 MPa or less, about 30 MPa or less, About 28 MPa or less. It should be understood that the cross-directional stiffness of the nonwoven material, such as a spunlaced polyester based material, may be in the range between any of the minimum and maximum values.

In certain instances, a nonwoven material, such as a spunlaced polyester based material of the support 102, has a specific porosity that implements certain finishing processes and features of the coated abrasive particles of the embodiments herein. For example, in one embodiment, the porosity of the nonwoven material, such as a spunlaced polyester based material, is less than or equal to about 25 vol% relative to the total volume of the support 102. In another embodiment, the porosity of the nonwoven material, such as a spunlaced polyester material, is less than or equal to about 20 vol%, such as less than or equal to about 15 vol%, less than or equal to about 12 vol%, less than or equal to about 10 vol% Or less, about 6 vol% or less, or about 4 vol% or less. In another embodiment, the porosity of the nonwoven material, such as the spunlaced polyester material of the support 102, is at least about 1 vol%, such as at least about 2 vol%, at least about 4 vol%, at least about 6 vol% About 8 vol%, or at least about 10 vol%. It should be understood that the porosity of the nonwoven material, such as the spunlaced polyester material of the support 102, may be in the range between any of the minimum and maximum values.

The nonwoven material of the support is subjected to one or more processes to form a coated abrasive article according to embodiments herein. Referring again to Figure 1, as shown, the support 102 comprising a nonwoven material (e.g., a spunlaced polyester-based material) may have one or more finishes, such as a saturating process, It goes through. In the saturation process, the saturant 130 is introduced into the non-woven material voids of the support 102. The saturating process includes the step of supporting the nonwoven material on the saturant for a period of time sufficient to ensure that the nonwoven material is saturated with the saturant. After saturating, the support comprising the nonwoven material and the saturant is heat treated to cure the saturant material. The heat treatment may be performed by a controlled heating process at about 100 캜 to a curing temperature, and at a predetermined saturating agent at about 150 캜 to about 190 캜. The controlled heating process may limit uncontrolled expression of moisture and blistering of the support.

According to a particular embodiment, the saturant may be contained within the voids of the nonwoven material, in particular in the voids of the spunlaced polyester based material. In certain instances, the saturant may be a material selected from the group consisting of phenolic resin, acrylic, urea resin, and combinations thereof. According to one embodiment, the saturant comprises substantially (at least about 98%) urea-formaldehyde resin.

The saturant agent extends substantially uniformly over the entire volume of the nonwoven material (e.g., spunlaced polyester material) of the support 102. For example, the saturant 130 extends substantially uniformly over the entire thickness 105 of the nonwoven material (e.g., a spunlaced polyester material) of the support 102. Also, in certain instances, the saturant 130 is disposed substantially within the void of a nonwoven material (e.g., a spunlaced polyester-based material). In other structures according to embodiments of the present invention, the saturant 130 is distributed substantially uniformly over the entire volume of the nonwoven material (e.g., spunlaced polyester material), and the saturant 130 is distributed over the major surface 104 ), The lower major surface 103, and the inner volume of the support 102.

In yet other instances, the saturating process is performed such that the saturating agent 130 is non-uniformly distributed in a particular region of the support 102. For example, in at least one embodiment, the saturant 130 is non-uniformly dispersed over the entire volume of the nonwoven material of the support 102 (e.g., a spunlaced polyester based material). By way of example, in some embodiments, the saturant 130 extends substantially non-uniformly over the entire thickness 105 of the nonwoven material (e.g., a spunlaced polyester material). In yet another alternative embodiment, the saturating agent 130 may be applied to a support 102 nonwoven material (e.g., a spunlaced polyester (e.g., (For example, the upper major surface 104) of the base material (base material). The content of the saturating agent 130 is higher than that of the non-woven material (for example, spunlaced polyester material) (E. G., Top surface 104). ≪ / RTI > For example, an inner region, such as a middle region 111, which extends parallel to the major surfaces of the support 102 and defines a plane extending between the upper major surface 104 and the lower major surface 103 of the support 102, In comparison, the content of the saturating agent (130) may be larger in a nonwoven material (for example, a spunlaced polyester material) main surface. In a more specific embodiment, the saturation process may be performed in a specific manner such that the saturating agent 130 content at the top major surface 104 is different from the saturating agent 130 content at the bottom major surface 103. In certain instances, the content of the saturant 130 in the upper major surface 104 is greater than the content of the saturant 130 in the lower major surface 103.

The support has a specific saturant / support content ratio (Cs / Cp) that provides for the formation of the coated abrasive article of the embodiments herein. Cb " is the weight percent of the saturant 130 relative to the total weight of the support 102 and " Cb " is the weight of the support 102 in the nonwoven material (e.g., Polyester-based material). According to an embodiment, the support has a saturant / support content ratio of about 1 or less. In other instances, the saturant / support content ratio is less than about 0.9, such as less than about 0.8, less than about 0.7, less than about 0.6, less than about 0.5, less than about 0.4, less than about 0.35, less than about 0.3, About 0.2 or less, about 0.15 or less, about 0.1 or less, or about 0.08 or less. In another non-limiting embodiment, the saturant / support content ratio is at least about 0.01, such as at least about 0.02, at least about 0.03, at least about 0.05, at least about 0.08, or at least about 0.1. It is to be understood that the saturant / support content ratio can range between any of the minimum and maximum values.

According to one embodiment, the saturant has a specific surface density that realizes the formation of a coated abrasive article having the features of the embodiments of the present disclosure. For example, the surface density of the saturant may be at least 5 grams per square meter (i.e. g / m² or GSM), such as at least about 10 GSM, such as at least about 20 GSM, at least about 30 GSM, It is about 50 GSM. In yet another embodiment, the surface density of the saturant is less than or equal to about 200 GSM, such as less than about 150 GSM, less than about 100 GSM, less than about 90 GSM, less than about 80 GSM, or less than about 70 GSM. It should be understood that the face density of the saturant may be in the range between any of the minimum and maximum values.

In certain embodiments, the support 102 comprising a nonwoven material, a saturant, and optional additives has a specific porosity. For example, in one embodiment, the porosity value of the support 102 is at least about 0.1 sec / air back cc, which is measured based on a standard porosity test using a Texto Crafts Air air permeability tester. The porosity measurement test procedure is performed by first raising the equipment cylinder to the ready position and securing the support material between the two clamping plates at 0.0 second. The cylinder is released until it comes to a stop, and measurement is started at this time (t1). The equipment is sealed and the initial indication is marked M1. The cylinder continues to fall until the set position is reached, the measurement is stopped, and M2 and t2 are recorded. The porosity of the support is calculated as: [(t2-t1) / (M1-M2)] x100 and reported as 100 cc per second of air. In another embodiment, the porosity value of the support 102 is at least about 0.5 seconds / 100 cc, such as at least about 1 second / 100 cc, at least about 2 seconds / 100 cc, at least about 4 seconds / 100 cc, 100 cc, at least about 10 seconds / 100 cc, at least about 12 seconds / 100 cc, at least about 15 seconds / 100 cc, or at least about 20 seconds / 100 cc. In a non-limiting embodiment, the porosity value of the support 102 is less than or equal to about 100 seconds / 100 cc, such as less than or equal to 90 seconds / 100 cc, less than or equal to about 80 seconds / 100 cc, less than or equal to about 60 seconds / About 40 sec / 100 cc or less. It should be appreciated that the porosity value of the support 102 can range between any of the minimum and maximum values.

In addition, the support may have a specific absorbency value that realizes the formation of a coated abrasive article having features of embodiments of the present embodiments, which is measured according to the Cobb test using a Cobb Size tester. The test procedure for measuring the absorbance value of the support is to prepare two samples and measure the sample weight to 0.01 grams. The sample is labeled P or C to indicate the printed or coated surface. The sample is fixed to the equipment with a fixed plate rubber surface, the support surface is held on the rubber surface of the fixing plate, and is held upward. Spin the assembly to the test position and pour 100 cc distilled water into the sample in 0.0 seconds. The test time is 60 seconds. Turn the sample to the release position and drop the sample for 50-55 seconds. Remove the excess and wind the sample back and forth once. The sample is folded inward to the area tested (ie, wet), and the sample is quickly weighed again. Repeat for the opposite side. For example, in one example, the absorbance value of the support 102 is less than about 60, such as less than about 55, less than about 50, less than about 45, less than about 40, less than about 35, In another embodiment, the absorbance value of the support is at least about 1, such as at least about 5, or at least about 8. It is to be understood that the absorbance value of the support 102 may be in the range between any of the minimum and maximum values.

In certain instances, the nonwoven material (e.g., a spunlaced polyester based material) of the support 102 has a specific machine-direction shear modulus that realizes the formation of a coated abrasive article having features of the embodiments of the present disclosure. For example, the machine direction shear modulus of the nonwoven material (e.g., a spunlaced polyester material) of the support 102 is at least about 100 MPa when measured using an Instron 5982 as a 2 kN load cell. The total sample length of the sample is 200 mm, the sample width is 25 mm, the gauge length is 127 mm, and the strain is tested at 300 mm / min. The elastic modulus values are obtained from the stress-strain data. In yet another embodiment, the machine direction shear modulus of the support 102 nonwoven material is less than or equal to about 90 MPa, such as less than or equal to about 80 MPa, less than or equal to about 70 MPa, or less than or equal to about 60 MPa. In yet another embodiment, the machine direction shear modulus of the support 102 nonwoven material is at least about 10 MPa, such as at least about 20 MPa, at least about 30 MPa, or at least about 40 MPa. It is to be understood that the machine direction shear modulus of the support 102 non-woven material may range between any of the minimum and maximum values.

In another embodiment, the nonwoven material (e.g., a spunlaced polyester based material) of the support 102 has a specific cross-direction shear modulus that realizes the formation of a coated abrasive article having the features of the embodiments of the present disclosure. For example, the cross-direction shear modulus of the support 102 nonwoven material is less than or equal to about 15 MPa, such as less than or equal to about 12 MPa, less than or equal to about 10 MPa, less than or equal to about 9 MPa, or less than or equal to about 8 MPa. In another non-limiting embodiment, the cross-direction shear modulus of the support 102 nonwoven material is at least 1 MPa, such as at least about 2 MPa, at least about 3 MPa, or at least about 4 MPa. It is to be understood that the cross-direction shear modulus of the support 102 non-woven material can range between any of the minimum and maximum values.

Further, according to an embodiment, the support comprises at least one additive. For example, some suitable additives include catalysts, coupling agents, charging agents, antistatic agents, suspending agents, anti-loading agents, lubricants, wetting agents, dyes, fillers, viscosity modifiers, dispersants, default worse, do. It is to be understood that the support may comprise one or more of the combinations of additives described herein. The additives may be provided by any suitable method known to those skilled in the art.

The support also has a specific average thickness that realizes the formation of a coated abrasive article having the features of the embodiments of the present invention. For example, the average thickness of the support comprising the nonwoven material and the additive (e.g., saturant) is about 10 mm or less, such as about 9 mm or less, about 8 mm or less, about 7 mm or less, about 6 mm or less, About 5 mm or less, about 4 mm or less, about 3 mm or less, about 2 mm or less, or about 1 mm or less. In another non-limiting embodiment, the average thickness of the support is at least about 0.05 mm, such as at least about 0.08 mm, at least about 0.1 mm, at least about 0.2 mm, at least about 0.3 mm, or at least about 0.5 mm. It should be appreciated that the average thickness of the support can range between any of the minimum and maximum values.

After formation of a support comprising a nonwoven material, an optional saturant, and an optional filler, additional layers may be formed on the support 102. That is, one or more optional layers of material may optionally be disposed on or on one or more major surfaces of the support 102. For example, in one embodiment, the body 101 includes an optional optional frontfill layer 121 overlying the major surface of the support 102, e.g., the top major surface 104. In a specific example, the front fill layer 121 directly contacts the main surface of the support 102, e.g., the top major surface 104. More specifically, in certain embodiments, the front fill layer 121 directly engages and abuts the main surface of the support 102, for example, the upper major surface 104 of the support 102.

In certain embodiments, the front fill layer 121 comprises an organic material. More specifically, the front fill layer 121 is formed of a material such as a phenol resin, an epoxy resin, a urea resin, a polyurethane, a polyamide, a polyethylene, a polyacrylate, a polymethacrylate, a polyvinyl chloride, Cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and combinations thereof. According to one particular embodiment, the front fill layer 121 is made from a phenolic resin, an epoxy resin, a urea resin, and combinations thereof. In particular, the front fill layer 121 is substantially made of phenolic resin. In an alternative embodiment, the front fill layer 121 is substantially comprised of an epoxy resin. In another example, the front fill layer 121 is substantially made of urea resin. In other examples, the front fill layer 121 is substantially comprised of polyethylene, such as high density polyethylene.

According to one particular embodiment, the front fill layer 121, in certain instances, the mixture used to form the front fill layer 121 itself comprises a mixture of an acrylic resin, a phenolic resin, and certain additives, The content does not exceed 100 wt%. For example, in one embodiment, the front fill layer 121 comprises at least about 5 wt% acrylic resin based on the total weight of the mixture or front fill layer 121. In other instances, the acrylic resin in the mixture is used to form the front fill layer 121, and in certain instances, the front fill layer 121 itself comprises at least about 10 wt%, at least about 15 wt%, at least about 20 wt , At least about 25 wt%, or at least about 30 wt%. In another non-limiting embodiment, the front fill layer 121, in some instances the mixture used to form the front fill layer 121 itself, is less than or equal to about 70 wt%, such as less than or equal to about 60 wt% wt% or less of acrylic resin. It is to be understood that in the front fill layer 121, in certain instances, the acrylic resin content in the mixture used to form the final formed front fill layer 121 may be in the range between any of the maximum and minimum percentages.

As described herein, the front fill layer 121, in certain instances, the mixture used to form the final-formed front fill layer 121 is at least about (preferably about) about the total weight of the mixture or make coat 231 0.1 wt% of acrylic resin. In other examples, in the make-coat, and in certain instances, the phenolic resin in the mixture used to form the final-formed make coat 231 is at least about 1 wt. , At least about 5 wt%, at least about 8 wt%, at least about 10 wt%, such as at least about 15 wt%, or at least about 18 wt%. In yet another non-limiting embodiment, the front fill layer 121, in some instances, the mixture used to form the front fill layer 121 itself comprises up to about 70 wt%, such as up to about 60 wt% Or less, or about 30 wt% or less of a phenolic resin. It is to be understood that in the front fill layer 121, and in certain instances, the phenolic resin in the mixture used to form the final-formed front fill layer 121 may be in the range between any of the maximum and minimum percentages.

As described further herein, the front fill layer 121 and, in certain instances, the mixture used to form the front fill layer 121 itself may contain a certain amount of additive, such as, but not limited to, And calcium carbonate. According to at least one embodiment, the front fill layer 121 and, in certain instances, the mixture used to form the front fill layer 121 itself is at least about 0.1 < RTI ID = 0.0 > wt%, such as at least about 5 wt%, at least about 10 wt%, at least about 20 wt%, or at least about 40 wt% of the additive. In another non-limiting embodiment, the front fill layer 121, in some instances the mixture used to form the front fill layer 121 itself, is less than or equal to about 70 wt%, less than or equal to about 60 wt% wt% or less of additives (for example, calcium carbonate). It is to be understood that in the front fill layer 121, and in certain instances, the additive content in the mixture used to form the final-formed front fill layer may be in the range between any of the maximum and minimum percentages.

Also, in the front fill layer 121, and in certain instances, the mixture used to form the front fill layer 121 itself may contain a predetermined amount of an increasing agent, such as, but not limited to, a carbonate, such as an anionic thickener . According to at least one embodiment, the front fill layer 121 and, in certain instances, the mixture used to form the front fill layer 121 itself is at least about 0.1 < RTI ID = 0.0 > wt%, such as at least about 0.5 wt%, or at least about 0.8 wt%. In another non-limiting embodiment, the front fill layer 121, in some instances, the mixture used to form the front fill layer 121 itself, is less than or equal to about 10 wt%, such as less than or equal to about 6 wt% 3 wt% or less. It is to be understood that in the front fill layer 121, and in certain instances, the increment content in the mixture used to form the final-formed front fill layer may be in the range between any of the maximum and minimum percentages.

In addition, the front fill layer may have a specific structure for realizing the formation of a coated abrasive article having features of the embodiments herein. For example, the surface density of the front fill layer 121 is at least 1 gram per square meter (i.e., g / m² or GSM). At least about 10 GSM, at least about 15 GSM, at least about 20 GSM, at least about 20, GSM, at least about 25 GSM, at least about < RTI ID = 0.0 > 30 GSM, at least about 35 GSM, at least about 40 GSM, or at least about 45 GSM. In yet another embodiment, the surface density of the front fill layer 121 is less than about 100 GSM, e.g., less than about 90 GSM, less than about 80 GSM, less than about 70 GSM, less than about 60 GSM, or about 50 GSM. It should be understood that the surface density of the front fill layer 121 may be in the range between any of the minimum and maximum values.

1, the support 102 includes a backfill layer 122 overlying the support 102 side, and more specifically, the lower major surface 103 of the support 102, Lt; RTI ID = 0.0 > and / or < / RTI > The backfill layer 122 directly contacts the main surface of the support 102, e.g., the lower major surface 103 of the support 102. In this particular example, The backfill layer 122 may be formed of an organic material such as a phenolic resin, an epoxy resin, a urea resin, a polyurethane, a polyamide, a polyethylene, a polyacrylate, a polymethacrylate, a polyvinyl chloride, a polysiloxane, Acetate, nitrocellulose, natural rubber, starch, shellac, low density polyethylene, high density polyethylene, and combinations thereof. In at least one embodiment, the backfill layer 122 is comprised of substantially high density polyethylene. Backfill layer 122 has optional front fill layer 121 properties of the embodiments herein, including, but not limited to, surface density.

Referring again to Figure 1, as described herein, the coated abrasive article 100 includes an abrasive layer 107 overlying the support 102. According to an embodiment, the abrasive layer 107 comprises at least one coating layer overlying the support 102. Examples of some suitable coating layers include makecoats, size coats, pre-sized coats, supersize coats, and combinations thereof. It is to be understood that any one of the coating layers is optional.

Figure 2 includes a partial cross-sectional view of a coated abrasive article according to an embodiment. As shown in FIG. 2, the coated abrasive article 200 includes a body 201. The body 201 includes a support 202 having any of the features of the support described in the embodiments herein. In addition, the support 202 includes a major surface, and more specifically, an upper major surface 204. The body 201 further includes an optional layer 221 overlying the support 202, which in certain instances may be a front-fill layer and has any features of the front-fill layer according to embodiments herein. The body 201 further includes an intermediate layer 225 overlying the support 202. The intermediate layer 225 may be an optional layer. The intermediate layer 225 may also be directly bonded to the main surface of the support 202, for example, to the upper major surface 204 of the support 202. However, in alternative embodiments, one or more intervening layers, e.g., an optional layer 221, are disposed between the intermediate layer 225 and the support 202.

According to one embodiment, the intermediate layer 225 includes a variety of materials including but not limited to inorganic materials, organic materials, polymers, cloths, paper, films, fabrics, fleeced fabrics, , Woven materials, nonwoven materials, webbing, polymers, resins, phenolic resins, phenol-latex resins, epoxy resins, polyester resins, urea formaldehyde resins, polyesters, polyurethanes, polypropylenes, Combinations. In one particular embodiment, the intermediate layer comprises a fabric material, such as a fabric, such as a woven cotton material.

In at least one embodiment, the intermediate layer 225 comprises a woven material and the average surface density of the woven material is at least about 10 g / m 2. In other embodiments, the face density of the intermediate layer 225 cotton material is at least about 20 g / m 2 or at least about 30 g / m 2. In another embodiment, the cotton density of the cotton material is less than about 150 g / m², such as less than about 120 g / m², or less than about 100 g / m². It should be understood that the surface density of the intermediate layer 225 may be in the range between any of the minimum and maximum values.

2, the coated abrasive article 200 includes a body 201 that includes an abrasive layer 207 overlying the support 202. As shown in FIG. As shown, the abrasive layer 207 is in contact with the support 202 and includes one or more intervening layers, e.g., an optional layer 221, disposed between the support 202 and the abrasive layer 207, And an intermediate layer 225. However, in certain other instances, the abrasive layer 207 is in direct contact with and adjoining the upper major surface 204 of the support 202.

According to an embodiment, the abrasive layer 207 comprises a coating layer overlying the support 202. The coating layer comprises one or more material layers or films that adhere the abrasive particles 209 to the support 202. For example, some suitable coating layers include at least one of a make coat, a size coat, a pre-size coat, a supersize coat, and combinations thereof. The coating layer is formed by one or more processes as understood by those skilled in the art and includes, but is not limited to, deposition, coating, rolling, gravure, curing, radiating, heating, and combinations thereof.

In particular, referring to the coated abrasive article of FIG. 2, the abrasive layer 207 comprises a coating layer including a make coat 231. The make coat 231 rests on the support 202 and more particularly to the upper main surface 204 of the support 202. [ As will be appreciated, in certain instances, the make coat 231 may be formed by one or more intervening layers, e.g., optional layer 221 and / or intermediate layer 225, Can be spaced and indirectly coupled. In an alternative embodiment, the make coat 231 may be connected directly to at least a portion of the support 202, e.g., the upper major surface 204 of the support 202.

According to the embodiment, the make coat 231 includes an organic material. Some suitable organic materials include polymeric materials, and more particularly those selected from the group consisting of phenolic resins, acrylics, urea resins, epoxy resins, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides, polyethylenes, polysiloxanes, Cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and combinations thereof.

According to one particular embodiment, the make coat 231 comprises a mixture of a phenolic resin, an acrylic resin, and at least one additive to effect the formation of a coated abrasive article having the features of the embodiments herein. It should be understood that although a range of components is provided, the total weight does not exceed 100%. In the make-coat 231 and, in certain instances, the mixture used to form the final make-coat 231 composition is such that the ratio of the phenolic resin weight percentage to the acrylic resin weight percentage based on the total weight of the make- At least about 2: 1, at least about 3: 1, at least about 4: 1, or at least about 6: 1. In another embodiment, the ratio of phenolic resin to acrylic resin weight percentage is about 20: 1 or less, about 18: 1 or less, or about 14: 1 or less. The ratio of phenolic resin to acrylic resin may range between any of the above ratios.

More specifically, in make-up 231 and, in certain instances, the mixture used to form make-coat 231 itself comprises at least about 10 wt% phenolic resin relative to the total weight of mixture or make-coat 231 . In other examples, in a make coat, and in certain instances, the phenolic resin content in the mixture used to form make coat 231 itself is at least about 15 wt%, at least about 20 wt%, at least about 25 wt% About 30 wt%, or at least about 35 wt%. In another non-limiting embodiment, the make coat 231, in certain embodiments, in the mixture used to form the make coat 231 itself, the phenolic resin content is up to about 70 wt%, up to about 60 wt%, or Can be about 50 wt% or less. It should be appreciated that in make-up 231 and, in certain instances, the phenolic resin content in the mixture used to form the make-make 231 may be in the range between any of the maximum and minimum percentages.

In yet another embodiment, the makeup 231 and, in certain instances, the mixture used to form the finally-formed make coat 231 is at least about 0.1 wt% acrylate based on the total weight of the mixture or make coat 231 Resin. In other examples, the makeup coat, and in certain instances, the acrylic resin content in the mixture used to form the finally-formed make coat 231 is at least about 1 wt%, at least about 2 wt%, at least about 2.5 wt% , At least about 3 wt%, such as at least about 3.5 wt%. In another non-limiting embodiment, the makeup coat 231, in certain embodiments, the mixture used to form make coat 231 itself, has an acrylic resin content of less than about 30 wt%, less than about 20 wt% 10 wt%, or less, or about 7 wt% or less. It should be understood that in the make coat 231, and in certain instances, the acrylic resin content in the mixture used to form the finally-formed make coat 231 may be in the range between any of the maximum and minimum percentages.

In certain instances, in make-up 231, and in some instances, the mixture used to form make-up 231 itself comprises a certain amount of an oxide additive, such as, but not limited to, iron oxide. According to at least one embodiment, in the makeup 231, and in certain embodiments, the mixture used to form the makeup 231 itself, the iron oxide content is at least about 0.1 (based on the total weight of the mixture or make coat 231) wt%, such as at least about 0.2 wt%, at least about 0.3 wt%, at least about 0.4, or at least about 0.5 wt%. In another non-limiting embodiment, the make-up coat 231, in certain embodiments, the mixture used to form make coat 231 itself, has an iron oxide content of less than about 7 wt%, less than about 3 wt% 1.5 wt% or less. It should be appreciated that in make-up 231, and in certain instances, the iron oxide content in the mixture used to form the finally-formed make coat 231 may be in the range between any of the maximum and minimum percentages.

As further described herein, the makeup 231 and, in certain instances, the mixture used to form the make coat 231 itself may contain a predetermined amount of additive, such as, but not limited to, a carbonate such as calcium carbonate . According to at least one embodiment, in makeup 231 and, in certain instances, the mixture used to form makeup 231 itself, the additive content is at least about 0.1 wt.% (Based on the total weight of the mixture or make coat 231) , Such as at least about 5 wt%, at least about 10 wt%, at least about 20 wt%, at least about 40 wt%, or at least about 50 wt%. In another non-limiting embodiment, the makeup 231, in certain embodiments, the mixture used to form the make coat 231 itself, has an additive (e.g., calcium carbonate) content of about 70 wt% About 60 wt% or less, or about 55 wt% or less. It should be appreciated that in make-up 231, and in certain instances, the additive content in the mixture used to form the finally-formed make-coat 231 may be in the range between any of the maximum and minimum percentages.

As further shown in FIG. 2, the body 201 includes an abrasive layer 207, which includes a coating layer including a size coat 232. Particularly, the size coat is placed on a part of the make coat 231. More particularly, the size coat 232 is also placed over at least a portion of the abrasive grains 209 to secure the abrasive grains 209 to the support 202. According to certain embodiments, the size coat 232 is directly connected to a portion of the abrasive grains 209.

According to an embodiment, the size coat 232 comprises an organic material. Some suitable organic materials include polymeric materials, and more particularly those selected from the group consisting of phenolic resins, acrylics, urea resins, epoxy resins, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides, polyethylenes, polysiloxanes, Cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and combinations thereof.

According to one particular embodiment, size coat 232 comprises a mixture of phenolic resin, acrylic resin, and additives. It is understood that the range of these components is included in the total weight of the size coat 232 material that does not exceed 100%. The size coat 232, and, in certain instances, the amount of phenolic resin weight percentage based on the total weight of components in size coat 232, in the mixture used to form the final-formed size coat 232 composition, The ratio is at least about 1: 1 (wt% phenolic resin: wt% acrylic resin), such as at least about 2: 1, at least about 3: 1, at least about 4: 1, or at least about 6: In another embodiment, the ratio of phenolic resin to acrylic resin weight percentage is about 20: 1 or less, about 18: 1 or less, or about 14: 1 or less. The proportion of phenolic resin to acrylic resin in the mixture or in the final-formed size coat 232 may be in the range between any of the above ratios.

More specifically, the size coat 232 and, in certain instances, the mixture used to form the size coat 232 itself comprises at least about 10 wt% phenolic resin based on the total weight of the mixture or size coat 232 . In other instances, the size coat 232 and, in certain instances, the phenolic resin content in the mixture used to form the final-formed size coat 232 is at least about 15 wt%, such as at least about 20 wt% 25 wt%, at least about 30 wt%, or at least about 40 wt%. In another non-limiting embodiment, the size coat 232, in certain embodiments, the mixture used to form the size coat 232 itself, has a phenolic resin content of up to about 70 wt%, such as up to about 60 wt% Or about 55 wt% or less. It should be appreciated that in size coat 232, and in certain instances, the phenolic resin content in the mixture used to form the final-formed size coat 232 may be in the range between any of the maximum and minimum percentages.

In yet another embodiment, the size coat 232 and, in certain instances, the mixture used to form the final-formed size coat 232 is at least about 0.1 wt% acrylic resin (by weight based on the total weight of the mixture or size coat 232) . In other instances, the size coat 232 and, in certain instances, the acrylic resin content in the mixture used to form the final-formed size coat 232 is at least about 1 wt%, at least about 2 wt%, at least about 2.5 wt%, at least about 3 wt%, such as at least about 3.5 wt%. In another non-limiting embodiment, the size coat 232, in some embodiments, the mixture used to form the size coat 232 itself, has an acrylic resin content of up to about 30 wt%, up to about 20 wt% 10 wt% or less, or about 7 wt% or less. It should be appreciated that in size coat 232, and in certain instances, the acrylic resin content in the mixture used to form the final-formed size coat 232 may be in the range between any of the maximum and minimum percentages.

In certain instances, the size coat 232 and, in certain instances, the mixture used to form the size coat 232 itself comprises a predetermined amount of additive, such as an oxide, such as iron oxide. In at least one embodiment, the size coat 232 and, in certain instances, the mixture used to form the size coat 232 itself, has an iron oxide content of at least about 0.1 wt%, such as at least about 0.2 wt% About 0.3 wt%, at least about 0.5, or at least about 0.8 wt%. In another non-limiting embodiment, the size coat 232, in some embodiments, the mixture used to form the size coat 232 itself, has an iron oxide content of less than about 7 wt%, less than about 5 wt% 3 wt% or less. It should be appreciated that in size coat 232, and in certain instances, the iron oxide content in the mixture used to form the final-formed size coat 232 may be in the range between any of the maximum and minimum percentages.

Additionally, in size coat 232, and in certain instances, the mixture used to form size coat 232 itself comprises a certain amount of additive, such as, but not limited to, carbonate, such as calcium carbonate. According to at least one embodiment, in the size coat 232 and, in certain instances, the mixture used to form the size coat 232 itself, the additive content is at least about 0.1 wt. , Such as at least about 5 wt%, at least about 10 wt%, at least about 20 wt%, at least about 40 wt%, or at least about 50 wt%. In another non-limiting embodiment, the size coat 232, in some embodiments, in the mixture used to form the size coat 232 itself, the additive (e.g., calcium carbonate) content is up to about 70 wt% About 60 wt% or less, or about 55 wt% or less. It should be appreciated that in size coat 232, and in certain instances, the additive content in the mixture used to form the final-formed size coat 232 may be in the range between any of the maximum and minimum percentages.

Referring again to Figure 2, the coated abrasive article 200 includes a body 201, which includes abrasive particles 209 that rest on the support 202. More particularly, abrasive particles can be secured to a support using one or more layers as described in the embodiments herein. According to an embodiment, abrasive particles 209 include polycrystalline materials, amorphous materials, and combinations thereof. The abrasive grains 209 can be any mineral abrasive grain material or mineral abrasive composition known in the art. Examples of suitable abrasive compositions include non-metals, inorganic materials such as nitrides, oxides, carbides, borides, oxynitrides, superabrasive materials and combinations thereof. In another example, abrasive particles 209 include oxides such as aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, cerium oxide, and combinations thereof. In at least one particular embodiment, the abrasive particles 209 comprise alumina, and more particularly, substantially consist of alumina. According to one aspect, the abrasive particles 209 comprise a seeded sol-gel based abrasive material. For example, a suitable seeded sol-gel material comprises a polycrystalline material and the average grain size is less than about 1 占 퐉. In embodiments, abrasive particles 209 may be abrasive grit, abrasive grains, abrasive agglomerates, abrasive aggregates, or a combination thereof, which may be included in a polymeric binder formulation of abrasive layer 207. In addition, diamond, diamond-like carbon, and related carbon-based materials such as fullerite and aggregated diamond nano-rods, including certain synthetic diamond, for example, are included in the abrasive layer 207 in more detail It should be understood that the abrasive particles 209 may be used as abrasive particles 209. [ The abrasive grains 209 also include natural minerals such as garnet, cristobalite, quartz, corundum, feldspar. Further, in certain embodiments of the present invention, two or more different abrasive grain blends may be used in the same abrasive.

Coated abrasive articles include abrasive particles having an irregular-shaped contour similar to the abrasive particle shape obtained through conventional milling processes. The abrasive particles also include, for example, shaped abrasive particles having a machined contour including, but not limited to, polygons. In one particular embodiment, the abrasive particles comprise shaped abrasive particles having a substantially triangular two-dimensional shape. It should also be appreciated that the coated abrasive article may comprise various abrasive particle combinations, such as, for example, combinations of shaped abrasive particles and non-shaped abrasive particles.

In addition, the coated abrasive article of embodiments herein includes a single layer of abrasive particles 209 in an open-coat or closed-coat configuration. For example, a plurality of abrasive grains 209 form an open-coat abrasive having a coating density of abrasive grains of about 70 particles / cm ² or less. In other instances, the density of abrasive grains 209 per square centimeter of open-coated abrasive article is about 65 particles / cm ² or less, such as about 60 particles / cm ² or less, about 55 particles / cm ² or less, About 50 particles / cm ² or less. Further, in one non-limiting embodiment, the density of the open-coat coated abrasive article using abrasive particles 209 is at least about 5 particles / cm ² , or at least about 10 particles / cm ² . It should be appreciated that the density of abrasive particles 209 per square centimeter of open-coat coated abrasive article may be in the range between the minimum and maximum values

In an embodiment of the alternative, a plurality of abrasive particles 209 in the coating density of the abrasive particles 209 at least about 75 particles / cm ^2, for example at least about 80 particles / cm ^2, at least about 85 particles / cm ² , At least about 90 particles / cm ² , or at least about 100 particles / cm ² . Further, in one non-limiting embodiment, the density of the closed-coat coated abrasive articles using abrasive particles herein is less than about 500 particles / cm ² . It should be understood that the density of abrasive grains 209 per square centimeter of the closed-coat abrasive article can be in the range between the minimum and maximum values.

In certain instances, the open-coat coating density of the abrasive particles covering the outer abrasive surface of the article in the coated abrasive article is about 50% or less. In other embodiments, the percentage of abrasive-coated cloth relative to the total area of the polishing surface is about 40% or less, about 30% or less, about 25% or less, or about 20% or less. Further, in one non-limiting embodiment, the percentage of abrasive-coated cloth relative to the total area of the polishing surface is at least about 5%, such as at least about 10%, at least about 15%, at least about 20%, at least about 25% 30%, at least about 35%, or at least about 40%. It is to be understood that the coverage percentage of the shaped abrasive particles relative to the total area of the polishing surface can be in the range between said minimum and maximum values

Some of the embodiments of the coated abrasive article have a certain amount of abrasive particles relative to the length of the support or substrate (e.g., ream). For example, in one embodiment, the abrasive article applies a normalized weight of abrasive particles of at least about 20 lbs / rim, such as at least about 25 lbs / rim, or at least about 30 lbs / rim. Further, in one non-limiting embodiment, the abrasive grain normalized weight of the abrasive article is less than about 60 lbs / lim, such as less than about 50 lbs / lim, or less than about 45 lbs / lim. It should be appreciated that the abrasive article of the embodiments of the present embodiments may have a normalized abrasive grain normalized weight in the range between the minimum and maximum values

According to one embodiment, the abrasive grain surface density of the coated abrasive article may range from about 90 GSM to about 260 GSM for abrasive grain grit sizes ranging from about 36 grit to about 120 grit. The surface density is particularly accurate when the abrasive grains are deposited on a support in a gravity coating process. In other examples, the abrasive particle surface density on the coated abrasive article may range from about 230 gsm to about 370 gsm for abrasive particle grit sizes ranging from about 36 grit to about 120 grit. The surface density is particularly accurate when using electrostatic coating processes.

The abrasive layer 207 may be formed by forming a mixture comprising one or more coating layers of the abrasive layer (e.g., make coat 231 and / or size coat 232) formulation and abrasive particles 209, (202). ≪ / RTI > The process of combining the abrasive particles and the one or more coating layers comprises a polishing slurry forming step comprising abrasive particles 209 and one or more coating layer polymeric binder materials and / or additives. The polishing slurry also includes a solvent such as water or an organic solvent. The polishing slurry may contain other components such as organic solvents, a thixotropic agent, a dual-function material, a crosslinking agent, a surfactant, a chain transfer agent, a stabilizer, a dispersant, a hardener, a reaction medium, a pigment, , And fillers. In an embodiment, the slurry comprises a polymeric binder, an abrasive particulate material, one or more organic solvents, one or more catalysts, and one or more crosslinking agents. In another embodiment, the polishing slurry may optionally comprise a surfactant.

Once the slurry is properly formed, it may be laminated onto a support or one or more intermediate layers. The abrasive slurry containing abrasive particles and coating layer material is preferably applied to a support using a blade spreader to form a coating. Alternatively, the coating process may be a die, such as a slot die, a smooth roll, a gravure, or an inverse gravure coating method. The coating thickness range is from about 1 to about 5 mils (mils) after drying. Since the support is fed below the blade spreader at the desired coating speed, the polishing slurry can be applied to the support at the desired thickness.

In another embodiment, a coating layer comprising, for example, a make coat 231 mixture is first applied to the support (or other intervening layers) and the abrasive particles 209 are applied to the surface of the support, Quot; or < / RTI > a gravitational coating process). Both methods are well understood in the art, and generally the make coat is first laminated on a support, the abrasive grains are then laminated, and then the size coat is laminated. Optionally, the super-size coat may be laminated on top of the size coat.

The one or more coating layers may be treated with one or more finishing processes, including, but not limited to, curing, irradiation, heating, and the like, to form a suitable coating layer (e.g., a make coat). In another example, it should be understood that the make coat 231, the abrasive particles 209, and the size coat 232 are formed independently of each other and are successively laminated with discrete layers. The one or more coating layers are partially or fully cured. Additional molding or forming proceeds to the partially cured coating before complete curing. Generally, in the curing process, the coatings are heated to less than about 100 ° C to less than about 250 ° C. In certain embodiments, the curing step is preferably conducted at less than about 200 < 0 > C. Further, the process includes partial curing, for example, the make coat and the abrasive particles are laminated on the support and a partial curing process is performed. Thereafter, one or more additional layers, such as a size coat, may be formed on top of the make coat, and then the make coat and additional layers are fully cured together in a final, total cure process.

The various materials that may be used in the polishing slurry or other constituent layers of the coated abrasive article of the embodiments of the present disclosure are described in greater detail but are not limited.

Suitable polymeric binder materials include, but are not limited to, polyesters, epoxy resins, polyurethanes, polyamides s, polyacrylates, polymethacrylates, polyvinyl chloride, polyethylene, polysiloxane, silicone, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, And mixtures thereof. The polymeric binder mixture comprises more than one polymeric resin from the class of polymeric resins; For example, the polyester resin may be a mixture of copolyester resins. In an embodiment, the polymeric binder comprises a copolyester having a bisphenol structure in the copolyester skeleton. The copolyester may have less than 50 wt% polymeric binder, about 50 wt% polymeric binder, or greater than 50 wt% polymeric binder.

In an embodiment, the polymeric binder comprises a single copolyester resin, multiple copolyester resins, or mixtures thereof, which have a bisphenol structure in the copolyester resin or resin framework. In certain embodiments, the copolyester may be a single copolyester resin having a bisphenol moiety in the copolyester resin backbone. In another particular embodiment, the copolyester can be a mixture of two different copolyester resins, one of which has a bisphenol moiety in the copolyester resin backbone. In another embodiment, the copolyester comprises a plurality of copolyesters each having a bisphenol moiety in the backbone.

In certain embodiments, the bisphenol moiety in the copolyester skeleton can be one selected from the group consisting of bisphenol-A (2,2-bis (4-hydroxyphenyl) propane), bisphenol AP (1, (2,2-bis (4-hydroxyphenyl) hexafluoropropane), bisphenol-B (2,2-bis (4-hydroxyphenyl) butane), bisphenol-BP (bis- (4-hydroxyphenyl) diphenylmethane), bisphenol- Bis (4-hydroxyphenyl) ethane), bisphenol-F (bis (4-hydroxydiphenyl) methane), bisphenol- Bis (4-hydroxyphenyl) propane), bisphenol-M (1,3-bis ), Bisphenol-P (1,4-bis (2- (4-hydroxyphenyl) -2-propyl) benzene), bisphenol-PH (5,5 '- (1-methylethylidene) (1,1-bis (4-hydroxyphenyl) -3,3,5-trimethyl-cyclohexane), bisphenol-Z 1,1-bis (4-hydroxyphenyl) -cyclohexane), and any combination thereof.

The content of bisphenol structure in the copolyester skeleton is variable. For example, the content of the bisphenol structure is at least 3 wt% to 75 wt% of the copolyester backbone.

In an embodiment, the polymeric binder further comprises a polymeric portion that is crosslinked with the polymeric binder. The polymer moiety that is crosslinked with the polymeric binder may be: a reactive component for the formation of amino polymers or aminoplast polymers, such as alkylating urea-formaldehyde polymers, melamine-formaldehyde polymers, and alkylated benzoguanamine-formaldehyde polymers; Acrylate polymers such as acrylate and methacrylate polymers, alkyl acrylates, acrylated epoxies, acrylated urethanes, acrylated polyesters, acrylated polyethers, vinyl ethers, acrylate oils, or acrylated silicones ; Alkylated polymers such as urethane alkylated polymers; Polyester polymers; Reactive urethane polymers; Phenolic polymers such as resole and novolac polymers; Phenol / latex polymers; Epoxy polymers such as bisphenol epoxy polymers; Isocyanate; Isocyanurate; Polysiloxane polymers such as alkylalkoxysilane polymers; Or a reactive vinyl polymer. The moiety that is crosslinked to the polymeric binder includes monomers, oligomers, polymers, or combinations thereof. The portion bridged to the polymeric binder includes polymeric systems such as ultraviolet (UV) curable polymeric systems. In an embodiment, the polymeric binder further comprises a polymeric portion bridged with a polymeric binder, wherein the polymeric portion is selected from the group consisting of bisphenol-A; Epoxy; Phenol formaldehyde; Blocked isocyanate; Urea formaldehyde; Novolac; Resole; Resorcinol-formaldehyde; UV curable hybrid acrylic epoxy composition; And any combination thereof.

The portion of the polymer that is crosslinked with the polymeric binder constitutes from about 0.5 wt% to about 50 wt% of the total weight of the polymeric binder.

The bisphenol moiety content in the polymeric binder is variable. The bisphenol moiety content is at least 3 wt% to 75 wt% of the polymeric binder.

In an embodiment, the total amount of polymeric binder in the polishing slurry is at least about 10 wt%, at least about 12 wt%, at least about 13 wt%, at least about 14 wt%, or at least about 15 wt%. In yet another embodiment, the total amount of polymeric binder in the polishing slurry is less than about 20 wt%, less than about 19 wt%, less than about 18 wt%, or less than about 17 wt%. The total amount of polymeric binder in the polishing slurry may be in a range including any pair of the upper and lower limits. In certain embodiments, the polymeric binder content in the polishing slurry is at least about 10 wt% to about 20 wt% or less.

In certain embodiments, the polyester resin may be used in one or more constituent layers of a coated abrasive article of an embodiment. Suitable polyester resins include linear, saturated copolyester resins that are amorphous and highly-soluble in standard solvents such as methyl ethyl ketone (2-butanone) (MEK), toluol, ethyl acetate, and acetone. Alternatively, other suitable polyester resins have a limited solubility in semi-crystalline to crystalline products and are applied with solvents such as 1,3 dioxolane or tetrahydrofuran (THF). In embodiments, the polyester resin may be a thermoplastic, high molecular weight, aromatic, linear saturated copolyester resin. For example, Vitel 2210 (entirety owned by Rohm and Haas Company, Dow Chemical, Philadelphia, Pennsylvania, USA), Skybon ES-120 (SK Chemicals, South Korea or Worthen Industries, Nashua, New Hampshire, USA) ES-995 (SK Chemicals, South Korea or Worthen Industries, Nashua, New Hampshire, USA). In embodiments, the polyester resin content in the polishing slurry is at least about 5.0 wt%, at least about 8.0 wt%, or at least about 10 wt%. In another embodiment, the polyester resin content in the polishing slurry is less than about 20 wt%, less than about 19 wt%, less than about 18 wt%, or less than about 17 wt%. The polyester resin content in the polishing slurry may be in a range including any pair of the upper and lower limits. In certain embodiments, the polyester resin content range in the polishing slurry is at least about 10 wt% to about 20 wt%, or at least about 10 wt% to about 18 wt%, or at least about 12 wt% to about 17 wt% Or less.

In an embodiment, the polymeric binder is one of the group consisting of a polyester resin, a copolyester resin, a mixture of at least one copolyester resin, and combinations thereof. In another embodiment, the polymeric binder is a single copolyester resin. In certain embodiments, the polymeric binder is a mixture of two different copolyester resins (i.e., the first copolyester resin and the second copolyester resin). In another embodiment, the first copolyester resin may be a hard resin and the second copolyester resin may be a soft resin. In another embodiment, the ratio of the first copolyester resin to the second copolyester resin can be from about 9: 1 to about 0.25: 1.

The polymeric binder of the polishing slurry may be partially soluble (i.e., " diluted ") with the solvent to further improve workability and may have a certain proportion of solid range, or viscosity, depending on the application. Suitable organic solvents are those which dissolve the resin of the polishing slurry and are, for example, ketones, ethers, polar aprotic solvents, esters, aromatic solvents and linear and cyclic aliphatic hydrocarbons. Exemplary ketones include methyl ethyl ketone (2-butanone) (MEK), acetone, and the like. Exemplary ethers include alkoxyalkyl ethers such as methoxymethyl ether or ethyl ether, tetrahydrofuran, 1,4 dioxane, and the like. Polar aprotic solvents include dimethylformamide, dimethylsulfoxide, and the like. Suitable esters include alkyl acetates such as ethyl acetate, methyl 65 acetate and the like. Aromatic solvents include alkylaryl solvents such as toluene, xylene and others, and halogenated aromatics such as chlorobenzene and the like. Solvents of the hydrocarbon type include, for example, hexane, cyclohexane, and the like. A preferred organic solvent is methyl ethyl ketone. In embodiments, the organic solvent content in the polishing slurry is at least about 5.0 wt%, at least about 6.0 wt%, at least about 7.0 wt%, or at least about 8.0 wt%. In yet another embodiment, the organic solvent content in the polishing slurry is less than about 68 wt%, less than about 67 wt%, less than about 66 wt%, less than about 65 wt%, or less than about 64 wt%. The organic solvent content in the polishing slurry may be in a range including any pair of the upper and lower limits. In certain embodiments, the organic solvent content in the polishing slurry is at least about 5.0 wt% to about 68 wt%.

Suitable surfactants are those that have low water solubility and amphiphilic properties. In an embodiment, the lecithin is a surfactant. In embodiments, the surfactant content in the polishing slurry or any other constituent layer of the coated abrasive article described herein is at least about 0.1 wt%, at least about 0.125 wt%, or at least about 0.15 wt%. In another embodiment, the surfactant content in the polishing slurry is less than about 0.5 wt%, less than about 0.4 wt%, less than about 0.375 wt%, or less than about 0.35 wt%. The surfactant content in the polishing slurry may be in a range including any pair of the upper and lower limits. In certain embodiments, the surfactant content range in the polishing slurry is at least about 0.1 wt% to about 0.5 wt% or less.

Suitable catalysts (i.e., catalysts) are materials that promote polymerization. In an embodiment, the catalyst is an amine neutralized mixture of sulfonic acids. In another embodiment, the catalyst may be a tetravalent diorganotin. One or more catalysts or catalyst mixtures may be used in the polishing slurry mixture or any other constituent layer of the coated abrasive article described herein. In an embodiment, the catalyst content in the polishing slurry is at least about 0.01 wt%, at least about 0.015 wt%, or at least about 0.0175 wt%. In another embodiment, the catalyst content in the polishing slurry (or any constituent layer) is less than about 0.04 wt%, less than about 0.0375 wt%, less than about 0.035 wt%, or less than about 0.0325 wt%. The catalyst content in the polishing slurry may be in a range including any pair of the upper and lower limits. In certain embodiments, the range of catalyst content in the polishing slurry is at least about 0.01 wt% to about 0.04 wt% or less.

Suitable cross-linking agents are those which promote crosslinking of the polymeric binder material in the polishing slurry. In particular, the crosslinking agent may promote crosslinking of the polyester resin, or the epoxy resin, or a combination thereof. The cross-linking agent of the polishing slurry or any other constituent layer of the coated abrasive article described herein is an isocyanate and includes, for example, a polyisocyanate. In another embodiment, the crosslinking agent is a methylated melamine. In embodiments, the cross-linker content in the polishing slurry or any other constituent layer of the coated abrasive article described herein is at least about 0.2 wt%, at least about 0.3 wt%, or at least about 0.4 wt%. In another embodiment, the crosslinker content in the polishing slurry is less than about 1.0 wt%, less than about 0.8 wt%, or less than about 0.7 wt%. The cross-linker content in the polishing slurry or any other constituent layer of the coated abrasive article described herein may be in a range including any pair of the upper and lower limits. In certain embodiments, the range of crosslinker content in the polishing slurry is at least about 0.1 wt% to about 1.0 wt% or less.

Figure 7 illustrates a coated abrasive article dispensing system according to an embodiment. In one particular embodiment, the system 700 includes a distributor 701 having an opening 702 therein. The system 700 further includes a coated abrasive article 703 that is disposed within the dispenser 701 and dispensed by the user through the opening 702 from the dispenser 701. The coated abrasive article 703 includes any features of the coated abrasive article of the embodiments. In addition, the coated abrasive article 703 may be rolled within the dispenser 701 and withdrawn from the dispenser 701 as a single sheet.

In one particular example, the coated abrasive article 703 comprises a first set of perforations 704. A size selection for a portion of the coated abrasive article 703 is implemented with the first perforation 704. For example, the user withdraws a desired amount of coated abrasive article 703 from dispenser 701 and breaks the coated abrasive article 703 into a suitable working size. In particular, if a user wishes to separate a portion 715 of the coated abrasive article 703 from the portion 716 of the coated abrasive article, the user can tear the portion 715 from the portion 715 in the first set of perforations 704 . Thus, the coated abrasive article 703 can be dispensed in a size-selective manner, and the first set of perforations 704 allows the user to select a portion of the coated abrasive article of various sizes.

According to one embodiment, the first set of perforations 704 extend in a substantially straight path in the direction of the body abscissa 706 of the coated abrasive article 703. As generally shown, for a generally sheet-like shaped coated abrasive article 703, the length defines the longest dimension of the body extending in the longitudinal axis 707 direction. The body width of the sheet-like coated abrasive article 703 forms a second longest dimension extending in a transverse axis 706 extending in a direction substantially perpendicular to the length and longitudinal axis 707. Also, the perforations 704 of the first set extend in a straight path forming a perforation axis and are substantially parallel to the transverse axis 706 of the body of the coated abrasive article 703. The perforations 704 of the first set form a perforation axis, which extends across the body. 7, the perforations 704 of the first set may be used to define the overall width of the coated abrasive article 703, and more specifically, the overall width of the coated abrasive article 703, Lt; / RTI > It should also be appreciated that the perforations 704 of the first set need not extend in a straight path. By way of example, the first puncture 704 is assumed to extend, for example, but not exclusively, through a non-straight path including a curved path.

As further shown, the coated abrasive article 703 comprises a second set of apertures 705. A size selection for a portion of the coated abrasive article 703 is realized with a second perforation 705. Particularly when the user wants to cut a portion 716 of the coated abrasive article 703 from the portion of the coated abrasive article 717 the user can pull the portion 715 from the portion 717 into the second set of apertures 705 . Thus, the coated abrasive article 703 is dispensed in a size-selective manner, and the second set of apertures 705 allows the user to select a portion of the various sizes of the coated abrasive article.

According to one embodiment, the second set of perforations 705 extend in a substantially straight path in the direction of the body abscissa 706 of the coated abrasive article 703. The second set of perforations 705 also extends in a straight path forming a perforation axis substantially parallel to the transverse axis 706 of the body of coated abrasive article 703. The perforations 705 of the second set form a perforation axis extending across the body. 7, the perforations 705 of the second set may be used to define the overall width of the coated abrasive article 703, and more particularly, the overall width of the coated abrasive article 703, Lt; / RTI > It should also be understood that the perforations 705 of the second set need not extend in a straight path. By way of example, the perforations 705 of the second set are assumed to extend, for example, but not exclusively, in a non-straight path including a curved path.

In addition, the perforations 705 of the second set are spaced a longitudinal length 708 from the perforations 704 of the first set. The vertical length determines the size of a portion (e.g., portion 716) between protrusion 704 of first set and protrusion 705 of second set. It should be appreciated that a variety of suitable longitudinal length 708 dimensions may be applied depending upon the application and customization of the coated abrasive article.

To be clear in connection with the embodiment of FIG. 7, FIG. 8 includes a partial cross-sectional view of a coated abrasive article according to an embodiment. As shown, Figure 8 includes a coated abrasive article 800 having a body 801. The body 801 includes a support body 802 and includes an upper major surface 804 and a lower major surface 803 opposite the upper major surface 804. The body 801 also includes an abrasive layer 807 overlying the support 802, and more specifically, the upper major surface 804 of the support 802. [ The abrasive layer 807 includes abrasive particles 809 and at least one adhesive layer 808 which bonds and adheres the abrasive particles 809 to the support 802.

As further shown in FIG. 8, the coated abrasive article 800 body 801 includes perforations 821. The perforations 821 may be a perforation set, such as a single perforation in the first set of perforations 704 and / or the second set of perforations 705, wherein all perforations in the set have the same properties as perforations 821. As shown, a set of perforations (e.g., perforations 704 in the first set and / or perforations 705 in the second set) associated with the perforations 821, and thus the perforations 821, Extends into the thickness (835) of the support body (802) across the major surface (803). In a particular example, perforations 821, and thus perforations (e.g., perforation 704 and / or perforations 705 in the second set) associated with perforations 821, And has a specific average depth 836 relative to the thicknesses of the predetermined layers and predetermined constituent layers of the body 801. [ In particular, it should be understood that although FIG. 8 shows a perforation 821 with a specific average depth 836, it is understood that other perforations and perforation of other tubing may have other suitable depths that may enable effective cutting of the coated abrasive article 800 do.

For example, in one embodiment, perforations 821, and thus perforations (e.g., perforations 704 in the first set and / or perforations 705 in the second set) associated with the perforations 821, And an average depth 836 that is a fraction of the thickness 835 of the support 802. It should be noted that the thickness of the support 802 802 refers to the average thickness. According to one particular embodiment, perforations 821, and thus perforations (e.g., perforations 704 in the first set and / or perforations 705 in the second set) associated with the perforations 821, 802 has an average depth 836 extending through the entire thickness so that the apertures 821 intersect the lower major surface 803 and the upper major surface 804 of the support.

Also, in one embodiment, the perforations 821, and thus perforations (e.g., perforations 704 in the first set and / or perforations 705 in the second set) associated with the perforations 821, And an average depth 836 that is a fraction of the thickness 837 of at least the coated abrasive article 800 body 801 including the abrasive layer 802 and the abrasive layer 807. For example, in one example, a set of perforations (e.g., perforations 704 in the first set and / or perforations 705 in the second set) associated with the perforations 821, and thus the perforations 821, 802 may have an average depth 836 extending from the bottom major surface 803 into the abrasive layer 807. According to one particular embodiment, perforations 821, and thus perforations (e.g., perforation 704 and / or perforation 705) associated with perforations 821, The perforations may extend generally in the body 801 of the coated abrasive article 800 that includes the support 802 and the abrasive layer 807. The abrasive article 804 may have an average depth 836 that extends substantially the entire thickness 837 of the abrasive article 801, .

In particular, it should be understood that the perforations may extend through the backfill layer, the front fill layer, the intermediate layer, the make coat layer, the size coat layer, and the like, though not limited to any of the constituent layers of the embodiments herein. In addition, any features of the perforations 821 are imparted to the perforation 704 of the first set, the perforations 705 of the second set, and any set of apertures of the coated abrasive article of embodiments herein.

Examples

Example 1

        A first coated abrasive article is formed in the configuration provided in Table 1 below and is shown collectively in Fig. In particular, the coated abrasive article 300 includes a body 301 that includes a support 302 comprising a non-woven material and a saturant contained in the non-woven material void, a front fill layer 321 overlying the support 302, And an abrasive layer over the front fill layer 321 and the support 302 and comprising a make coat 331, abrasive particles 309 and a size coat 332. [ The nonwoven backing material is a spunlaced polyester material having an average surface roughness of about 9 microns, an average machine-directional stiffness of about 140 MPa, an average cross-direction stiffness of about 16 MPa, an average machine direction shear modulus of about 51 MPa, the average cross-direction shear modulus is approximately 6 MPa. The spun lace polyester material undergoes a saturation process in which the nonwoven substrate is immersed in a saturant formulation consisting of approximately 99% urea-formaldehyde resin and 1% catalyst, followed by a controlled heating process to cure the saturant. In a regulated heating process, the temperature gradually rises from approximately 100 캜 to a final curing temperature of approximately 140 캜 to 160 캜. The surface density of the saturant is approximately 60 GSM.

The average mechanical-directional stiffness of the support comprising the spun lace polyester material and the saturant is about 300 MPa, the average cross-direction stiffness is about 20 MPa, the average machine direction shear modulus is about 110 MPa, and the average cross- The modulus of elasticity is approximately 7 MPa. The porosity value of the support including the spun lace polyester material and the saturant is approximately 4 sec / 100 cc, and the absorbance value is approximately 22%.

The front fill layer 321 is formed on the support by a process of coating the formulation onto the smoother side of the support at a running speed of 35 meters per minute using two roll coaters at room temperature with a viscosity of about 2000 cps (measured with a Brookfield viscometer) do. The support with the front fill is then cured by a controlled heating process in which the components are gradually heated to a final curing temperature of approximately 150 ° C to 170 ° C at approximately 100 ° C.

For reference, the materials referred to in Table 2 are the following materials obtained from the indicated manufacturer. Phenolic resins are commercially available as LTR phenolic resins and urea formaldehyde resins are commercially available as Wescamine M from West Coast Polymer. Iron oxide is available from Vinayak Auxi Chem as Red Oxide Liquid-TATA T110. The abrasive grains are alumina, available from Futon Imp. & Exp. Lt; / RTI > Calcium carbonate is available as CFL DURA from Mahaveer Chemicals or Kirti. The thickener is available ASE 60 from Mahalaskhmi Chemicals or Indofil. Acrylic resin is available from Rohm and Haas as TR407. Gray Dye is available under the name Amritlal Chemix. The catalyst is available as AMP 700 from Sri Gur Udeva Dutta Scientific.

The abrasive layer is formed on the support and the front fill layer, and includes a make coat, abrasive particles, and a size coat layer. The abrasive layer is formed by a process including the following steps: the make coat is laminated to the front fill, and the abrasive particles are laminated to the make coat. The make coat is partially cured by a controlled heating process that implements partial curing of the make coat formulation. The size coat is then provided on a make coat and the make coat and the size coat are treated in a controlled heating process to achieve full cure so that the make coat and the size coat are finally cured, Lt; / RTI >

Support Spun Lace Polyester (approximately 100-200 GSM) Urea formaldehyde and about 1 wt% catalyst-700 saturating agent Front fill Acrylic resin ~ 35% Calcium carbonate ~ 43% Incrementer ~ 1% Phenolic resin ~ 21% Make coat Phenolic resin ~ 41% Acrylic resin ~ 4% Calcium carbonate ~ 54% Iron oxide ~ 1% Abrasive particle Alumina Size coat Phenolic resin ~ 47% Acrylic resin ~ 5% Calcium carbonate ~ 47% Iron oxide ~ 2%

Example 2

A second coated abrasive article is formed in the configuration provided in Table 2 below and is shown comprehensively in FIG. In particular, the coated abrasive article 400 includes a body 401 that includes a support 402 comprising a nonwoven material, a front fill layer 421 overlying the support 302, a backfill layer 422 underlying the support 402, And an abrasive layer 407 over the front fill layer 421, the support 402 and the backfill layer 422 and including a make coat 431, abrasive grains 409 and a size coat 432 do. The nonwoven backing material is the same spunlaced material used in Example 1, and an extruded extruded polyolefin (polyethylene or polypropylene) layer is added to one side of the spunlaced polyester material as the backfill layer 422.

The average mechanical-orientation stiffness of the support including the spun lace polyester material and the polyolefin backfill layer 422 is about 300 MPa, the average cross-direction stiffness is about 20 MPa, the average machine direction shear modulus is about 110 MPa, The directional shear modulus is approximately 7 MPa. The porosity value of the support including the spun lace polyester material and the saturant is approximately 26 sec1 / 100 cc, and the absorbance value is approximately 27%. The front fill layer 421 and the abrasive layer 407 were formed on the support 402 in the same manner as described above in Example 1.

Support Spun Lace Polyester (approximately 100-200 GSM) Front fill Acrylic resin ~ 35% Calcium carbonate ~ 43% Incrementer ~ 1% Phenolic resin ~ 21% Backfill HDPE ~ 100% Make coat Phenolic resin ~ 41% Acrylic resin ~ 4% Calcium carbonate ~ 54% Iron oxide ~ 13% Abrasive particle Alumina Size coat Phenolic resin ~ 47% Acrylic resin ~ 5% Cab Dura ~ 47% Red Oxide ~ 2%

Example 3

A third coated abrasive article is formed in the configuration provided in Table 3 below and is shown collectively in Fig. In particular, the coated abrasive article 200 includes a body 201 that includes a support 202 comprising a non-woven material and a saturant contained within the non-woven material void, a front fill layer 221 overlying the support 202, An intermediate layer 225 of a cotton cloth having a surface density of about 50-150 GSM and a make coat 231 on the intermediate layer 225 and the front fill layer 221 and on the support 202, 209, and an abrasive layer 207 comprising a size coat 232. The nonwoven backing material was the same spun lace material used in Example 1 and saturated with a saturating agent in the same manner as in Example 1.

Support Spun Lace Polyester (approximately 100-200 GSM) Urea formaldehyde and a saturated agent of about 1 wt% catalyst Front fill Acrylic resin ~ 35% Calcium carbonate ~ 43% Incrementer ~ 1% Phenolic resin ~ 21% Middle layer 50GSM cotton fabric Make coat Phenolic resin ~ 41% Acrylic resin ~ 4% Calcium carbonate ~ 54% Iron oxide ~ 1% Abrasive particle Alumina Size coat Phenolic resin ~ 47% Acrylic resin ~ 5% Calcium carbonate ~ 47% Iron oxide ~ 2%

The average machine-direction stiffness of the support 202, including the spun lace polyester material and the saturant, is about 300 MPa, the average cross-direction stiffness is about 20 MPa, the average machine direction shear modulus is about 110 MPa, The shear modulus is approximately 7 MPa. Further, the porosity value of the support 202 including the spun lace polyester material and the saturator is approximately 1 sec / 100 cc, and the absorption value is approximately 26%.

The front fill layer 221 and the abrasive layer 207 are formed on the support 402 in the same manner as described above in Embodiment 1. [

The intermediate layer 225 was formed on the front-fill layer 221 using a lamination process with a hot-melt ethylene vinyl acetate (EVA) adhesive.

Conventional Example

Conventional coated abrasive article samples were obtained as Sand it all at Grindwell Norton. In particular, the coated abrasive article 500 has the structure shown in Fig. 5, which includes a body 501, which includes a support 502 comprising a saturate finished cotton fabric, a backfill layer < RTI ID = 0.0 > And an abrasive layer 507 over the backing layer 522 and including a make coat 531, abrasive grains 509, Saturated agents and backfill agents are provided in Table 4 below. Make-coat and size-coat preparations are substantially the same as those provided in Table 1.

Saturating agent Acrylic resin 47.3% Phenolic resin 52.0% Gray dye 0.2% catalyst 0.5% Backfill Urea formaldehyde resin 33.1% Calcium carbonate 33.1% Gray dye 0.1% catalyst 0.5% Acrylic resin 33.1%

FIG. 5 is a material ablation amount and a material grinding rate chart of an embodiment of the present invention as compared with, for example, a conventional product. The samples were tested according to the procedure given in Table 5 below. As shown, in Examples 1 and 2, which typically employ a nonwoven backing material that can reduce the amount of material removal and the material grinding rate, very remarkable and unexpectedly, the exemplary embodiments (i.e., Examples 1 and 2) 2) exhibit the same or better improvement over standard products using textile backing materials. Indeed, Example 1 was performed with conventional fabric products. More remarkably, Example 2 showed improved performance compared to the prior art including a woven support.

Step 1 Bob Ball / Teak (Babbol / Teak) wood board with dimensions of 150mm x 700mm x 25mm was obtained from the manufacturing process Step 2 Elimination of any fibers and protrusions on the surface. Step 3 Low air pressure eliminates dust blowing Step 4 Coating Abrasive Sample Sheet Cut to 1/4 Size Step 5 Sheet initial weight measurement Step 6 Fold sheet to fold around double density pad / wood block Step 7 Initial weighing Step 8 Grasp the sheet wrapped around the pads and start woodblock sanding (half length) Step 9 Particle dropout observed during the first 2 minutes while sanding Step 10 Sanding completed for 5 minutes Step 11 Low air pressure to remove dust blown on wood board Step 12 Wood plate, coated abrasive Sample sheet weighing and MR recording Step 13 Continue sanding at 5 minute intervals and weigh wood and sheet Step 14 When the material removal amount (MR) reaches 1 gram or less, Step 15 Repeat sanding twice for MR recording to confirm end of life. Step 16 Visual observation of sheet failure with microscope observation Step 17 All observed WRT stiffness during full sanding operation, cutting speed and grip record in sanding process

The embodiments are advanced from the art. Although spun lace materials have been proposed as potential materials in coating abrasives, these materials have typically not been used as support materials. In those cases where a spun lace material is used in a support, performance has not been technically or commercially applied, as it typically could not be compared to a coated abrasive article using a fabric support material. These embodiments include, but are not limited to, certain nonwoven materials having predetermined composition and characteristics, certain finishing processes including nonwoven material saturation, various structures such as the backfill layer, the front fill layer, the intermediate layer, the make coat, ≪ / RTI > and combinations thereof. Without being bound by any particular theory, the present inventors believe that the coated abrasive articles of the embodiments herein exhibit remarkable performance as compared to other conventional abrasive articles, including nonwoven substrate materials, and furthermore, The same or good performance was obtained as compared with the coated abrasive article.

The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. And may be modified or changed in light of the above teachings. The embodiments are chosen and described in order to provide the best illustration and practical application of the principles of the invention, and, accordingly, to enable those skilled in the art to utilize the invention in various modifications as are suited to the various embodiments and particular applications contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in a fair, legal and equitable manner.

Item 1. A coated abrasive article, comprising: a support body comprising a body and comprising: a saturant contained in a spunlaced polyester-based material and a spunlaced polyester-based material, wherein the saturant is selected from the group consisting of a phenolic resin, Resins, and combinations thereof; And an abrasive layer overlying the support and comprising abrasive particles.

Item 2. A coated abrasive article comprising: a body; a body: a support including a saturated agent contained in a spunlaced polyester material and a spunlaced polyester material; a surface density of the spunlaced polyester material Is at least about 50 grams per square meter (GSM) and not more than about 300 grams per square meter (GSM); And an abrasive layer overlying the support and comprising abrasive particles.

Item 3. A coated abrasive article, comprising: a body, the body including: a support further comprising a nonwoven material and a saturant contained within the nonwoven material, the machine-directional stiffness of the nonwoven material being at least about 80 MPa and about 220 MPa or less, the cross-direction stiffness is at least about 1 MPa and not more than about 40 MPa; And an abrasive layer overlying the support and comprising abrasive particles.

Item 4. In item 1, the surface density of the spunlaced polyester material of the support is at least about 50 grams per square meter (gsm), at least about 60 GSM, at least about 70 GSM, at least about 80 GSM, at least about 90 GSM At least about 100 GSM, at least about 110 GSM, at least about 120 GSM, at least about 130 GSM, at least about 140 GSM, at least about 150 GSM.

Item 5. In item 1, the surface density of the spunlaced polyester material of the support is less than or equal to about 300 grams per square meter (GSM), less than about 290 GSM, less than about 280 GSM, less than about 270 GSM, less than about 260 GSM , Less than or equal to about 250 GSM.

Item 6. The article of item 2 wherein the face density of the spunlaced polyester material of the support is at least about 60 GSM, at least about 70 GSM, at least about 80 GSM, at least about 90 GSM, at least about 100 GSM, At least about 120 GSM, at least about 130 GSM, at least about 140 GSM, at least about 150 GSM, and the face density of the spunlaced polyester base material of the support is less than about 290 GSM, less than about 280 GSM, less than about 270 GSM, GSM or less, about 250 GSM or less.

Item 7. The method of item 3 wherein the surface density of the nonwoven material of the support is at least about 50 GSM at least about 60 GSM, at least about 70 GSM, at least about 80 GSM, at least about 90 GSM, at least about 100 GSM, At least about 120 GSM, at least about 130 GSM, at least about 140 GSM, at least about 150 GSM, and the face density of the nonwoven material of the support is less than about 290 GSM, less than about 280 GSM, less than about 270 GSM, less than about 260 GSM, 250 GSM or less.

Item 8. The method of item 1 or 2 wherein the average thickness of the spunlaced polyester material is about 10 mm or less, about 9 mm or less, about 8 mm or less, about 7 mm or less, about 6 mm or less, about 5 mm or less, About 4 mm or less, about 3 mm or less, about 2 mm or less, about 1 mm or less, and the average thickness of the spunlaced polyester material is at least about 0.05 mm, at least about 0.08 mm, at least about 0.1 mm, , At least about 0.3 mm, at least about 0.5 mm.

Item 9. In item 3, the average thickness of the nonwoven material is less than about 10 mm, less than about 9 mm, less than about 8 mm, less than about 7 mm, less than about 6 mm, less than about 5 mm, less than about 4 mm, The average thickness of the nonwoven material is at least about 0.05 mm, at least about 0.08 mm, at least about 0.1 mm, at least about 0.2 mm, at least about 0.3 mm, at least about 0.5 mm Coated abrasive article.

Item 10. The method of any one of items 1, 2, and 3, wherein the average thickness of the support is less than about 10 mm, less than about 9 mm, less than about 8 mm, less than about 7 mm, less than about 6 mm, less than about 5 mm , About 4 mm or less, about 3 mm or less, about 2 mm or less, about 1 mm or less and an average thickness of the support is at least about 0.05 mm, at least about 0.08 mm, at least about 0.1 mm, at least about 0.2 mm, mm, at least about 0.5 mm.

Item 11. The article of any of items 1, 2, and 3, wherein the support comprises a generally planar upper major surface and the average surface roughness (Ra) of the upper major surface is less than about 20 microns, less than about 18 microns, less than about 15 microns , Less than about 12 microns, less than about 10 microns, and an average surface roughness (Ra) of the top major surface of at least about 1 micron.

Item 12. The article of any of items 1, 2, and 3, wherein the support comprises a generally flat lower major surface and the average surface roughness (Ra) of the lower major surface is about 30 microns or less, about 28 microns or less, about 25 microns or less Less than about 22 microns, less than about 20 microns, less than about 18 microns, and an average surface roughness (Ra) of the top major surface of at least about 5 microns.

Item 13. The coated abrasive article of any one of items 1, 2, and 3, wherein the support comprises a generally planar, non-wrinkled contour.

Item 14. The article of any of items 1, 2, and 3, wherein the support has a machine-directional stiffness of at least about 200 MPa, at least about 210 MPa, at least about 220 MPa, at least about 230 MPa, At least about 270 MPa, at least about 280 MPa, at least about 290 MPa and the machine-directional stiffness of the support is less than about 400 MPa, less than about 390 MPa, less than about 380 MPa, less than about 370 MPa , About 360 MPa or less, about 350 MPa or less.

Item 15. The article of any of items 1, 2 and 3, wherein the cross-directional stiffness of the support is at least about 1 MPa, at least about 2 MPa, at least about 3 MPa, at least about 4 MPa, at least about 5 MPa, 6 MPa, at least about 7 MPa, at least about 8 MPa at least about 10 MPa, and the cross-directional stiffness of the support is about 50 MPa or less, about 45 MPa or less, about 40 MPa or less, about 38 MPa or less, about 35 MPa or less, And less than or equal to about 33 MPa.

Item 16. The article of item 1 or 2 wherein the machine-directional stiffness of the spunlaced polyester material of the support is at least about 80 MPa, at least about 90 MPa, at least about 100 MPa, at least about 110 MPa, at least about 120 MPa, and Wherein the machine-directional stiffness of the spunlaced polyester material of the support is about 220 MPa or less, about 210 MPa or less, about 200 MPa or less, about 190 MPa or less, about 180 MPa or less, about 160 MPa or less.

Item 17. The method of item 1 or 2 wherein the cross-directional stiffness of the spunlaced polyester material of the support is at least about 1 MPa, at least about 2 MPa, at least about 3 MPa, at least about 5 MPa, And the cross-directional stiffness of the spunlaced polyester material of the support is about 40 MPa or less, about 38 MPa or less, about 35 MPa or less, about 33 MPa or less, about 30 MPa or less, about 28 MPa or less.

Item 18. The article of item 3, wherein the machine-directional stiffness of the nonwoven material of the support is at least about 90 MPa, at least about 100 MPa, at least about 110 MPa, at least about 120 MPa, Wherein the directional stiffness is about 210 MPa or less, about 200 MPa or less, about 190 MPa or less, about 180 MPa or less, about 160 MPa or less.

Item 19. The method of item 3 wherein the cross-directional stiffness of the nonwoven material of the support is at least about 2 MPa, at least about 3 MPa, at least about 5 MPa, at least about 8 MPa, Wherein the cross-directional stiffness is about 38 MPa or less, about 35 MPa or less, about 33 MPa or less, about 30 MPa or less, about 28 MPa or less.

Item 20. The method of item 1 or 2 wherein the porosity of the spunlaced polyester material is about 25 vol% or less, the porosity of the spunlaced polyester material is about 20 vol% or less, about 15 vol% , Less than about 12 vol%, less than about 10 vol%, less than about 8 vol%, less than about 6 vol%, less than about 4 vol%, and porosity of the spunlaced polyester material of the support is at least about 1 vol% At least about 2 vol%, at least about 4 vol%, at least about 6 vol%, at least about 8 vol%, and at least about 10 vol%.

Item 21. The method of item 3, wherein the porosity of the nonwoven material is less than about 25 vol%, the porosity of the nonwoven material is less than about 20 vol%, less than about 15 vol%, less than about 12 vol% about 8 vol% or less, about 6 vol% or less, about 4 vol% or less and the porosity of the spunlaced polyester material of the support is at least about 1 vol%, at least about 2 vol%, at least about 4 vol %, At least about 6 vol%, at least about 8 vol%, at least about 10 vol%.

Item 22. The method of item 1 or 2, wherein the saturant / support content ratio (Cs / Cb) of the support is about 1 or less, Cs represents the weight percentage of the saturant relative to the total weight of the support, (Cs / Cb) is about 0.9 or less, about 0.8 or less, about 0.7 or less, about 0.6 or less, about 0.5 or less, about 0.4 or less, about 0.35 (Cs / Cb) of at least about 0.01, at least about 0.02, at least about 0.03, at least about 0.03, at least about 0.3, at least about 0.25, at least about 0.2, at least about 0.15, at least about 0.1, , At least about 0.05, at least about 0.08, at least about 0.1.

Item 23. In item 3, the saturant / support content ratio (Cs / Cb) of the support is less than or equal to about 1, Cs is the weight percentage of the saturant relative to the total weight of the support, (Cs / Cb) is about 0.9 or less, about 0.8 or less, about 0.7 or less, about 0.6 or less, about 0.5 or less, about 0.4 or less, about 0.35 or less, (Cs / Cb) is at least about 0.01, at least about 0.02, at least about 0.03, at least about 0.10, at least about 0.10, at least about 0.08, and a saturant / About 0.05, at least about 0.08, and at least about 0.1.

Item 24. The method of any one of items 1, 2, and 3, wherein the porosity value of the support is at least about 0.1 sec / 100 cc according to a standardized porosity test and the porosity value of the support is at least about 0.5 sec / 100 cc At least about 1 sec / 100 cc, at least about 2 sec / 100 cc, at least about 4 sec / 100 cc, at least about 7 sec / 100 cc, at least about 10 sec / 100 cc, at least about 12 sec / At least about 20 seconds / 100 cc, and at least about 100 seconds / 100 cc, at least about 90 seconds / 100 cc, at least about 80 seconds / 100 cc, at least about 60 seconds / / 100 cc.

Item 25. The method of any one of items 1, 2, and 3, wherein the absorbance value of the support is less than or equal to about Cobb test and the absorbance value of the support is less than or equal to about 60, less than or equal to about 55, Less than about 40, less than about 35, less than about 30, and a substrate absorbance value of at least about 1, at least about 5, at least about 8.

Item 26. The method of item 1 or 2, wherein the machine-direction shear modulus of the spunlaced polyester material of the support is about 100 MPa or less, about 90 MPa or less, about 80 MPa or less, about 70 MPa or less, Wherein the machine directional shear modulus of the spunlaced polyester material is at least about 10 MPa, at least about 20 MPa, at least about 30 MPa, at least about 40 MPa.

Item 27. The method of item 1 or 2 wherein the cross-direction shear modulus of the spunlaced polyester material of the support is about 15 MPa or less, about 12 MPa or less, about 10 MPa or less, about 9 MPa or less, Wherein the cross-direction shear modulus of the lacy polyester-based material is at least about 1 MPa, at least about 2 MPa, at least about 3 MPa, at least about 4 MPa.

Item 28. The method of item 3, wherein the non-woven material of the support has a machine direction shear modulus of about 100 MPa or less, about 90 MPa or less, about 80 MPa or less, about 70 MPa or less and the spunlaced polyester material Wherein the machine direction shear modulus is at least about 10 MPa, at least about 20 MPa, at least about 30 MPa, at least about 40 MPa.

Item 29. The method of item 3 wherein the cross-direction shear modulus of the nonwoven material of the support is less than or equal to about 15 MPa, less than or equal to about 12 MPa, less than or equal to about 10 MPa, less than or equal to about 9 MPa, Wherein the cross-directional shear modulus is at least about 1 MPa, at least about 2 MPa, at least about 3 MPa, at least about 4 MPa.

Item 30. The method of item 1 or 2 wherein the saturant agent extends substantially uniformly over the entire volume of the spunlaced polyester material and the saturant agent extends substantially uniformly over the entire thickness of the spunlaced polyester material, Wherein the saturant is disposed within the voids in the spunlaced polyester-based material of the support.

Item 31. The method according to item 1 or 2, wherein the saturant is non-uniformly arranged over the entire volume of the spunlaced polyester material, the saturant is substantially non-uniformly extended over the entire thickness of the spunlaced polyester material, Is preferably arranged on the main surface of the spunlaced polyester material and the content of the saturant is different on the main surface of the spunlaced polyester material as compared with the inner area spaced from the main surface of the spunlaced polyester material, Lace polyester material Compared with the inner area to be spaced apart from the main surface, spun-lace polyester material More from the main surface, coated abrasive article.

Item 32. The method of item 3, wherein the saturant agent extends substantially uniformly over the entire volume of the nonwoven material, the saturant agent extends substantially uniformly over the entire thickness of the nonwoven material, Wherein the abrasive article is disposed inside the abrasive article.

Item 33. The method of item 3, wherein the saturant is non-uniformly disposed over the entire volume of the non-woven material, the saturant is substantially non-uniformly extended over the entire thickness of the non-woven material and the saturating agent is preferably disposed on the non- , The saturating agent content is different in the main surface of the non-woven material as compared with the inner area spaced apart from the main surface of the non-woven material, and the saturator content is larger in the main surface of the non-woven material as compared with the inner area spaced from the main surface of the non- ≪ / RTI > further comprising a material.

Item 34. The method of item 1, further comprising a front fill which is placed on the support main surface, wherein the front fill is in contact with the main surface of the support, the front fill is in contact with the main surface of the support, and the front fill is in the form of a phenol resin, , Polyamide, polyacrylate, polymethacrylate, polyvinyl chloride, polyethylene, polysiloxane, silicone, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and combinations thereof.

Item 35. The backfill as set forth in any one of Items 1, 2, and 3, further comprising a backfill placed on the support main surface, wherein the backfill is in contact with the main surface of the support, Wherein the polymeric material comprises a resin, a urea resin, polyurethane, polyamide, polyacrylate, polymethacrylate, polyvinyl chloride, polyethylene, polysiloxane, silicone, cellulose acetate, Wherein the backfill is substantially composed of low density polyethylene.

Item 36. The method of any of items 1, 2, and 3, wherein the support is selected from the group consisting of a catalyst, a coupling agent, a curant, an antistatic agent, a suspending agent, an anti-loading agent, a lubricant, a wetting agent, An additive selected from the group consisting of a dispersing agent, a defoaming agent, and a grinding aid.

Item 37. The method of any one of items 1, 2, and 3, wherein the abrasive layer comprises a coating layer overlying the support, wherein the coating layer comprises at least one of a make coat, a size coat, a pre-size coat, a supersize coat, Wherein the abrasive article is a coated abrasive article.

Item 38. The coated abrasive article of Item 37, wherein the make coat is placed on a support, the make coat is directly bonded to the support portion, and at least one layer of material is disposed between the make coat and the support.

Item 39. The method according to item 38, wherein the make coat comprises an organic material, the make coat comprises a polymer material, and the make coat is selected from the group consisting of phenol resin, acrylic resin, urea resin, epoxy resin, polyurethane, polyamide, Wherein the material comprises a material selected from the group consisting of polymethacrylate, polyvinyl chloride, polyethylene, polysiloxane, silicone, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and combinations thereof.

Item 40. The coated abrasive article of Item 37, wherein the coating layer comprises a size coat, the size coat is over a portion of the abrasive particles, the size coat is over the make coat, and the size coat is directly bonded to a portion of the abrasive particles.

Item 41. The method of item 40 wherein the size coat comprises an organic material, the size coat comprises a polymeric material, and the size coat is selected from the group consisting of phenolic resin, acrylic, urea resin, epoxy resin, polyurethane, polyamide, polyacrylate, Wherein the material comprises a material selected from the group consisting of polymethacrylate, polyvinyl chloride, polyethylene, polysiloxane, silicone, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and combinations thereof.

Item 42. The method of any one of items 1, 2, and 3, wherein the abrasive particles comprise a polycrystalline material, the polycrystalline material comprises a grain and the abrasive particles comprise nitride, oxide, carbide, Wherein the abrasive particles are selected from the group consisting of oxides, oxynitrides, superabrasives, and combinations thereof, wherein the abrasive particles are selected from the group consisting of aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, Wherein the abrasive particles comprise alumina. ≪ Desc / Clms Page number 18 >

Item 43. The method of any one of items 1, 2, and 3, wherein the abrasive particles comprise seeded sol-gel based abrasive particles and the abrasive particles comprise a polycrystalline material having an average grain size of about 1 micron or less Coated abrasive article.

Item 44. The coated abrasive article of any one of items 1, 2, and 3, wherein the abrasive particles comprise shaped abrasive particles and the abrasive particles comprise irregular-shaped abrasive particles.

Item 45. The method according to item 1 or 2, wherein the spunlaced polyester material comprises mostly polyester by volume and the spunlaced polyester material comprises at least about 75 vol% of the total volume of spunlaced polyester material Wherein the spunlaced polyester material comprises polyester, and the spunlaced polyester material is substantially comprised of polyester.

Item 46. The method according to item 46, wherein the non-woven material comprises a spun lace material, the non-woven material comprises a spun lace polyester material, most of the polyester is based on volume, and the spun lace polyester material is a spun lace Wherein the spunlaced polyester material comprises at least about 75 vol% of polyester relative to the total volume of the polyester-based material, and the spunlaced polyester material is substantially comprised of polyester.

Item 47. The method of any one of items 1, 2, and 3, wherein the intermediate layer further comprises an inorganic material, an organic material, a polymer, a cloth, a paper, a film, a fabric, a wool fabric, a cured fiber, A nonwoven material selected from the group consisting of a nonwoven material, a webbing, a polymer, a resin, a phenol resin, a phenol-latex resin, an epoxy resin, a polyester resin, a urea formaldehyde resin, a polyester, a polyurethane, a polypropylene, a polyimide, Wherein the intermediate layer comprises at least one material and the intermediate layer comprises a cotton material.

Item 48. The method of any one of items 1, 2, and 3, further comprising an open coat of abrasive particles on the support, wherein the coating density of the open coat is no greater than about 70 particles / cm2, no greater than about 65 particles / At least about 5 particles / cm2, at least about 10 particles / cm2, about 60 particles / cm2 or less, about 55 particles / cm2 or less, about 50 particles / cm2 or less.

Item 49. The method of any one of items 1, 2, and 3, further comprising a closed coat of abrasive particles on the support, wherein the coating density of the closed coat is at least about 75 particles / cm2, at least about 80 particles / At least about 85 particles / cm2, at least about 90 particles / cm2, at least about 100 particles / cm2.

Item 50. The coated abrasive article of any of items 1, 2, and 3, wherein the body comprises a first set of apertures.

Item 51. The coated abrasive article of Item 50, wherein the perforations of the first set extend across the support lower main surface to a support thickness.

Item 52. The coated abrasive article of Item 50, wherein the average depth of the perforations in the first set is at least a portion of the support thickness.

Item 53. The coated abrasive article of Item 50, wherein the average depth of the perforations in the first set is at least a portion of the body thickness.

Item 54. The coated abrasive article of Item 50, wherein the average depth of the perforations in the first set extends through the entire thickness of the support.

Item 55. The coated abrasive article of Item 50, wherein the average depth of the perforations in the first set extends from the lower major surface of the support to the abrasive layer.

Item 56. The coated abrasive article of Item 50, wherein the perforation of the first set defines a perforation axis extending transversely across the body.

Item 57. The article of Item 50, wherein the perforations in the first set extend substantially along a straight path.

Item 58. The article of Item 50, wherein the perforation of the first set extends along a curved path.

Item 59. The coated abrasive article of Item 50, wherein the perforation of the first set extends along the entire width of the support.

Item 60. The coated abrasive article of Item 50 further comprising a punch of the second set spaced apart from the punch of the first set.

Item 61. The coated abrasive article of Item 60, wherein the perforations in the second set extend across the support lower main surface to a support thickness.

Item 62. The coated abrasive article of Item 60, wherein the perforations in the second set are spaced along the body longitudinal axis from the perforations in the first set.

Item 63. The coated abrasive article of Item 60 wherein the average depth of the perforations in the second set is at least a portion of the support thickness.

Item 64. The coated abrasive article of Item 60, wherein the average depth of the perforations in the second set is at least a portion of the body thickness.

Item 65. The coated abrasive article of Item 60, wherein the average depth of the perforations in the second set extends through the entire thickness of the support.

Item 66. The coated abrasive article of Item 60, wherein the average depth of the perforations in the second set extends from the lower major surface of the support to the abrasive layer.

Item 67. The coated abrasive article of Item 60, wherein the perforations in the second set form a perforation axis extending transversely across the body.

Item 68. The article of item 60, wherein the perforations in the second set extend substantially along a straight path.

Item 69. The article of Item 60, wherein the perforations in the second set extend along a curved path.

Item 70. The coated abrasive article of Item 60, wherein the perforations in the second set extend along the entire width of the support.

Item 71. The coated abrasive article of Item 60 further comprising a longitudinal length between the perforations in the first set and the perforations in the second set.

Item 72. The coated abrasive article of Item 60, wherein the coated abrasive article is contained within a dispenser.

Item 73. The coated abrasive article of Item 60, wherein the coated abrasive article comprises a plurality of sets of perforations and is contained within the dispenser, and wherein the coated abrasive article is dispensed in a size-selective manner.

Item 74. A method of forming a coated abrasive article, comprising: forming a support by saturating a support preform comprising a spunlaced polyester material with a saturant, wherein the saturant is selected from the group consisting of a phenolic resin, acrylic, The material selected; And

And forming an abrasive layer overlying the support.

Claims (15)

A coated abrasive article comprising a body, the body comprising:
A support comprising a spunlaced polyester material and a saturant contained in the spunlaced polyester material, the saturant comprising a material selected from the group consisting of phenolic resin, acrylic, urea resin, and combinations thereof; And
A polishing abrasive article comprising: a polishing layer disposed on a support and comprising abrasive particles; The coated abrasive article of claim 1, wherein the surface density of the spunlaced polyester material is at least about 50 grams per square meter (GSM) and not more than about 300 grams per square meter (GSM). The coated abrasive article of claim 1, wherein the machine-directional stiffness of the spunlaced polyester material is at least about 80 MPa and not more than about 220 MPa, and the cross-directional stiffness is at least about 1 MPa and not greater than about 40 MPa. The coated abrasive article of claim 1, wherein the average thickness of the spunlaced polyester material is at least about 0.05 mm and not greater than about 10 mm. The coated abrasive article of claim 1, wherein the average thickness of the support is at least about 0.05 mm and not greater than about 10 mm. 2. The coated abrasive article of claim 1, wherein the support comprises a generally planar upper major surface, wherein the average major surface roughness (Ra) of the upper major surface is at least about 1 micron and not greater than about 20 microns. 2. The coated abrasive article of claim 1, wherein the support comprises a generally flat lower major surface, wherein the average major surface roughness (Ra) of the lower major surface is at least about 5 microns and not greater than about 30 microns. The coated abrasive article of claim 1, wherein the machine-directional stiffness of the support is at least about 200 MPa and not more than about 400 MPa. The coated abrasive article of claim 1, wherein the cross-directional stiffness of the support is at least about 1 MPa and not greater than about 50 MPa. The coated abrasive article of claim 1, wherein the porosity of the spunlaced polyester material is at least about 1 vol% and not more than about 25 vol% based on the total volume of the support. The coated abrasive article of claim 1, wherein the saturant / support content ratio (Cs / Cb) of the support is at least about 0.01 and less than or equal to about 1. The coated abrasive article of claim 1, wherein the porosity value of the support is at least about 0.1 sec / 100 cc according to a standardized porosity test. The coated abrasive article of claim 1, wherein the absorbency value of the support is at least about 1 and not more than about 60 according to the Cobb test. The coated abrasive article of claim 1, wherein the machine directional shear modulus of the spunlaced polyester material of the support is at least about 10 MPa and not more than about 100 MPa. The coated abrasive article of claim 1, wherein the cross-direction shear modulus of the spunlaced polyester material of the support is at least about 1 MPa and not more than about 15 MPa.

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