STRUCTURED ABRASIVE ARTICLE WITH INTERLAYER

Abstract

According to one aspect, an abrasive article includes a backing and an abrasive layer comprising shaped structures comprising abrasive particles and a binder, and an interlayer between the backing and the abrasive layer. The interlayer can have at least one of the following: an ILTave of at least 4 microns,an ILTmax of at least 5 microns, oran ILTmin of at least 3 microns.

Description

BACKGROUND

Field of the Disclosure

The following is directed to abrasive articles, and, in particular, structured abrasive articles.

SUMMARY

According to one aspect, an abrasive article includes a backing and an abrasive layer comprising shaped structures comprising abrasive particles and a binder; and an interlayer between the backing and the abrasive layer. The interlayer can have at least one of the following:

• • an ILT_ave of at least 4 microns,
  • an ILT_max of at least 5 microns, or
  • an ILT_min of at least 3 microns.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes an illustration of an abrasive article.

FIG. 2 includes an illustration of an abrasive layer and an interlayer of an abrasive article.

FIG. 3 includes a perspective view of a shaped structure and an interlayer of an abrasive article.

FIGS. 4a and 4b include illustrations of a method of depositing an abrasive slurry into a mold.

DETAILED DESCRIPTION

The following is directed to abrasive articles and more particularly, structured abrasive articles. The abrasive articles may be used in a variety of material removal operations for a variety of work pieces, but in particular, may be used for polishing automotive clear coats.

As seen in FIGS. 1 and 2, an abrasive article 100 can include a backing 130, an abrasive layer 101, and an interlayer 110 between the backing and the abrasive layer 101. The abrasive layer 101 can include shaped structures 105 comprising abrasive particles 106 and a binder 108.

The interface between the interlayer 110 and the abrasive layer 101 is at the height where adjacent shaped structures 105 contact each other. As can be seen in FIG. 3, this height can vary along the borders of shaped structures, with local minima occurring in the corner of shaped structures. For the purpose of consistency and accuracy, all interlayer thickness (ILT) measurements are taken in the corner of shaped structures where the local minima occur with the exception of ILT_diff which also involves a measurement at a local maxima. For all abrasive articles, at least 5 ILT measurements are taken. ILT_min is the lowest ILT that is taken on an abrasive article. ILT_max is the highest ILT measurement taken on an abrasive article. ILT_ave is the mean ILT measurement taken on an abrasive article. ILT₅₀ refers to the median ILT measurement taken on an abrasive article. ILT₈₀ refers to the 80th percentile ILT measurement taken on an abrasive article. ILT_diff refers to the average difference of ILT measurements taken at local minima, and measurements of the thickness at the interlayer at local maxima, which tend to occur in the middle of the long sides of each shaped feature as shown in FIG. 3.

In an embodiment, the interlayer 110 may have a particular ILT_ave that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the ILT_ave can be at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns or at least 8.5 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns. In an embodiment, the ILT_ave may be no greater than 40 microns or no greater than 35 microns or no greater than 30 microns or no greater than 25 microns or no greater than 20 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns. It will be appreciated that ILT_ave may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 4 microns and not greater than 17 microns or at least 6 microns and not greater than 9 microns.

In an embodiment, the interlayer 110 may have a particular ILT_min that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the ILT_min can be at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns. In an embodiment, the ILT_min may be no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns. It will be appreciated that ILT_min may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 4 microns and not greater than 17 microns or at least 6 microns and not greater than 9 microns.

In an embodiment, the interlayer 110 may have a particular ILT_max that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the ILT_max can be at least 5 microns or at least 6 microns or at least 7 microns or at least 8 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns. In an embodiment, the ILT_max may be no greater than 20 microns or no greater than 19 microns or no greater than 18 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns. It will be appreciated that ILT_max may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 8 microns and not greater than 17 microns or at least 6 microns and not greater than 14 microns.

In an embodiment, the interlayer 110 may have a particular ILT₅₀ that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the ILT₅₀ can be at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns or at least microns or at least 8.5 microns or at least 9 microns or at least 9.5 microns or at least 10 microns or at least 10.5 microns or at least 11 microns or at least 11.5 microns or at least 12 microns or at least 12.5 microns or at least 13 microns. In an embodiment, the ILT₅₀ may be no greater than 20 microns or no greater than 19 microns or no greater than 18 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns. It will be appreciated that ILT₅₀ may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 8 microns and not greater than 17 microns or at least 6 microns and not greater than 14 microns.

In an embodiment, the interlayer 110 may have a particular ILT₈₀ that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the ILT₈₀ can be at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns or at least microns or at least 8.5 microns or at least 9 microns or at least 9.5 microns or at least 10 microns or at least 10.5 microns or at least 11 microns or at least 11.5 microns or at least 12 microns or at least 12.5 microns or at least 13 microns. In an embodiment, the ILT₈₀ be no greater than 20 microns or no greater than 19 microns or no greater than 18 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns. It will be appreciated that ILT₈₀ may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 8 microns and not greater than 17 microns or at least 6 microns and not greater than 14 microns.

In an embodiment, the interlayer 110 may have a particular ILT_diff that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the ILT_diff can be at least 0.5 microns or at least 1 micron or at least 1.5 microns or at least 2 microns or at least 2.5 microns or at least 3 microns or at least 3.5 microns or at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns. In an embodiment, the ILT_diff be no greater than 13 microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns or no greater than 8 microns or no greater than 7 microns or no greater than 6 microns. It will be appreciated that ILT_diff may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 3 microns and not greater than 13 microns or at least 1.5 microns and not greater than 12 microns.

In an embodiment, the shaped structures 105 may have a particular shape that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the shaped structures may be pyramids. In an embodiment, the shaped structures 105 may be rectangular or square pyramids. In an embodiment, the shaped structures 105 may be rectangular pyramids. The pyramids can have a height, measured perpendicular to the backing, and length and width, measured parallel to the backing, where the length is greater than or equal to the width.

In an embodiment, the shaped structures 105 may have a particular height that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the shaped structures 105 can have a height of at least 5 microns or at least 6 microns or at least 7 microns or at least 8 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns or at least 15 microns or at least 16 microns or at least 17 microns or at least 18 microns or at least 19 microns or at least 20 microns or at least 21 microns or at least 22 microns or at least 23 microns or at least 24 microns or at least 25 microns or at least 26 microns or at least 27 microns or at least 28 microns or at least 29 microns or at least 30 microns or at least 31 microns or at least 32 microns or at least 33 microns or at least 34 microns or at least 35 microns. In an embodiment, the shaped structures 105 can have a height of no greater than 50 microns or no greater than 49 microns or no greater than 48 microns or no greater than 47 microns or no greater than 46 microns or no greater than 45 microns or no greater than 44 microns or no greater than 43 microns or no greater than 42 microns or no greater than 41 microns or no greater than 40 microns or no greater than 39 microns or no greater than 38 microns or no greater than 37 microns or no greater than 36 microns or no greater than 35 microns or no greater than 34 microns or no greater than 33 microns or no greater than 32 microns or no greater than 31 microns or no greater than 30 microns or no greater than 29 microns or no greater than 28 microns or no greater than 27 microns or no greater than 26 microns or no greater than 25 microns. It will be appreciated that the shaped structure 105 height may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 10, and not greater than 50 or at least 15 and not greater than 45.

In an embodiment, the shaped structures 105 may have a particular length that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the shaped structures 105 can have a length of at least 100 microns or at least 110 microns or at least 120 microns or at least 130 microns or at least 140 microns or at least 150 microns or at least 160 microns or at least 170 microns or at least 180 microns or at least 190 microns or at least 200 microns. In an embodiment, the shaped structures 105 can have a length of no greater than 400 microns or no greater than 375 microns or no greater than 350 microns or no greater than 325 microns or no greater than 300 microns or no greater than 275 microns or no greater than 250 microns. It will be appreciated that the shaped structure 105 length may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 100, and not greater than 375 or at least 140 and not greater than 250.

In an embodiment, the shaped structures 105 may have a particular width that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the shaped structures 105 can have a width of at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns or at least 15 microns or at least 16 microns or at least 17 microns or at least 18 microns or at least 19 microns or at least 20 microns. In an embodiment, the shaped structure 105 can have a width of no greater than 60 microns or no greater than 58 microns or no greater than 56 microns or no greater than 54 microns or no greater than 52 microns or no greater than 50 microns or no greater than 48 microns or no greater than 46 microns or no greater than 44 microns or no greater than 2 microns or no greater than 40 microns or no greater than 40 microns. It will be appreciated that the shaped structure 105 width may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 10, and not greater than 50 or at least 15 and not greater than 46. In an embodiment, the abrasive article 100 may have a particular average interlayer thickness to average structure height ratio that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the average interlayer thickness to average structure height ratio may be at least 1:10 or at least 1:5 or at least 1:4.5 or at least 1:4 or at least 1:3.5 or at least 1:3 or at least 1:2.5 or at least 1:2 or at least 1:1.5 or at least 1:1 or at least 1.5:1 or at least 2:1 or at least 2.5:1 or at least 3:1 or at least 3.5:1 or at least 4:1 or at least 4.5:1 or at least 5:1. In an embodiment, the average interlayer thickness to average structure height ratio may be of no greater than 5:1 or no greater than 4.5:1 or no greater than 4:1 or no greater than 3.5:1 or no greater than 3:1 or no greater than 2.5:1 or no greater than 2:1 or no greater than 1.5:1 or no greater than 1:1 or no greater than 1:1.5 or no greater than 1:2 or no greater than 1:2.5 or no greater than 1:3 or no greater than 1:3.5 or no greater than 1:4 or no greater than 1:4.5 or no greater than 1:5. It will be appreciated that the average interlayer thickness to average structure height ratio may be between any of the minimum and maximum values noted above, including for example, at least 1:10 and not greater than 5:1 or at least 1:2 and not greater than 1:1.

In an embodiment, the abrasive layer 101 may have a particular density of shaped structures that may facilitate improved performance and/or manufacturing of the abrasive article. The shaped structure density can be measured in structures per inch in the width direction (lpi_w), structures per inch in the length direction (lpi_l), or structures per mm². In an embodiment, the abrasive layer can include a shape structure density of at least 100 lpi_w or at least 150 lpi_w or at least 200 lpi_w or at least 250 lpi_w or at least 300 lpi_w or at least 350 lpi_w or at least 400 lpi_w or at least 450 lpi_w or at least 40 lpi_l or at least 45 lpi_l or at least 50 lpi_l or at least 55 lpi_l or at least 60 lpi_l or at least 65 lpi_l or at least 70 lpi_l or at least 75 lpi_l or at least 80 lpi_l or at least 85 lpi_l. In an embodiment, the abrasive layer can include a shape structure density of no greater than 800 lpi_w or no greater than 775 lpi_w or no greater than 750 lpi_w or no greater than 725 lpi_w or no greater than 700 lpi_w or no greater than 675 lpi_w or no greater than 650 lpi_w or no greater than 625 lpi_w or no greater than 600 lpi_w or no greater than 575 lpi_w or no greater than 550 lpi_w or no greater than 525 lpi_w or no greater than 500 lpi_w or no greater than 475 lpi_w or no greater than 200 lpi_l or no greater than 190 lpi_l or no greater than 180 lpi_l or no greater than 170 lpi_l or no greater than 160 lpi_l or no greater than 150 lpi_l or no greater than 140 lpi_l or no greater than 130 lpi_l or no greater than 120 lpi_l or no greater than 110 lpi_l or no greater than 100 lpi_l. It will be appreciated that the shaped structure density may be between any of the minimum and maximum values noted above. The shaped structure can also be 30-100 structures per mm², particularly when the structures have unequal length and width (i.e., are rectangular pyramids). Alternatively, the shaped structure can also be 100-450 structures per mm², particularly when the structures have equal length and width (i.e., are square pyramids).

The abrasive layer 101 and interlayer 110 may be prepared from a slurry 401 as shown in FIGS. 4a and 4b. The abrasive slurry 401 may be deposited and spread into a mold 405 via knife blade coater 410 or squeegee 420. After shaping with the mold, the abrasive layer and interlayer may be deposited directly on or over the backing. The abrasive layer and interlayer may be deposited directly onto a tie layer overlying the backing.

In an embodiment, the abrasive slurry may be deposited using a knife blade coater with a particular knife gap that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the knife gap may be 0 mil. In an embodiment, the knife gap may be at least 0 mils or at least 0.01 mil or at least 0.1 mil or at least 0.5 mil or at least 1 mil. In an embodiment, the knife gap may be no greater than 10 mil or no greater than 8 mil or no greater than 6 mil or no greater than 5 mil or no greater than 4.5 mil or no greater than 4 mil or no greater than 3.5 mil or no greater than 3 mil or no greater than 2.5 mil. It will be appreciated that the knife gap may be between any of the minimum and maximum values noted above.

In an embodiment, the abrasive particles 106 can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the abrasive particles 106 can comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof. In a particular embodiment, the abrasive particles 106 can comprise or consist of silicon carbide. In an embodiment, the abrasive particles can include a silane coating.

In an embodiment, the abrasive particles 106 may have a particular median particle size that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the abrasive particles can have a median particle size of at least 1 micron or at least 2 microns or at least 3 microns or at least 4 microns or at least 5 microns. In an embodiment, the abrasive particles can have a median particle size of no greater than 20 microns or no greater than 18 microns or no greater than 16 microns or no greater than 14 microns or no greater than 12 microns or no greater than 10 microns or no greater than 8 microns. It will be appreciated that the particle size of abrasive particles 106 may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 2 microns, and not greater than 18 microns or at least 5 microns and not greater than 12 microns.

In an embodiment, the binder 108 can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the binder 108 can radiation curable binder. In a particular embodiment, the binder 108 can comprise any epoxy, an acrylate, a methacrylate, polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), isocyanate, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, UV curable resins, or combinations thereof. In an embodiment, the binder 108 can include silane. In an embodiment, the binder 108 can include a photoinitiator.

In an embodiment, the binder 108 can include an additive that may facilitate improved performance and/or manufacturing of the abrasive article. The additive may comprise solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators, agents for influencing the fluidity of the dispersion, grinding aids, fillers, extenders, defoamers, surfactants, or combinations thereof.

As seen in FIG. 2, the interlayer 110 can include interlayer particles 116 and an interlayer binder 118. The interlayer 110 can have the same composition as the abrasive layer 101, or a different composition than the abrasive layer 101.

In an embodiment, the interlayer abrasive particles 116 can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the interlayer abrasive particles 116 can comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof. In a particular embodiment, the interlayer abrasive particles 116 can comprise or consist of silicon carbide. In an embodiment, the interlayer abrasive particles can include a silane coating. The interlayer particles 116 can be the same as the abrasive particles 106 or different than the abrasive particles 106.

In an embodiment, the interlayer abrasive particles 116 may have a particular median particle size that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the interlayer abrasive particles can have a median particle size of at least 1 micron or at least 2 microns or at least 3 microns or at least 4 microns or at least 5 microns. In an embodiment, the interlayer abrasive particles can have a median particle size of no greater than 20 microns or no greater than 18 microns or no greater than 16 microns or no greater than 14 microns or no greater than 12 microns or no greater than 10 microns or no greater than 8 microns. It will be appreciated that the particle size of interlayer abrasive particles 116 may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 2 microns, and not greater than 18 microns or at least 5 microns and not greater than 12 microns.

In an embodiment, the interlayer binder 118 can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the interlayer binder 118 can comprise a radiation curable interlayer binder. In a particular embodiment, the interlayer binder 118 can comprise any epoxy, an acrylate, a methacrylate, polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), isocyanate, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, UV curable resins, or combinations thereof. In an embodiment, the interlayer binder 118 can include silane. In an embodiment, the interlayer binder 118 can include a photoinitiator. The interlayer binder 118 can be the same as the binder 108 or different than the binder 108.

In an embodiment, the backing 130 can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the backing 130 can comprise a polymeric film (for example, a primed film), such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), polyester film (e.g., polyethylene terephthalate), polyamide film, or cellulose ester film; metal foil; mesh; foam (e.g., natural sponge material or polyurethane foam or polyester foam or polyolefin foam or PVC foam or silicone foam); cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; nonwoven materials; a combination thereof. In a more particular embodiment, the backing 130 may comprise foam. In an even more particular embodiment, the backing 130 may comprise a polyurethane foam.

In an embodiment, the backing 130 may have a particular density that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the backing may comprise a density of at least 50 kg/m³ or at least 52 kg/m³ or at least 54 kg/m³ or at least 56 kg/m³ or at least 58 kg/m³ or at least 60 kg/m³ or at least 62 kg/m³ or at least 64 kg/m³ or at least 66 kg/m³. In an embodiment, the backing may comprise a density of no greater than 175 kg/m³ or no greater than 170 kg/m³ or no greater than 165 kg/m³ or no greater than 160 kg/m³ or no greater than 155 kg/m³ or no greater than 150 kg/m³ or no greater than 145 kg/m³ or no greater than 140 kg/m³ or no greater than 135 kg/m³ or no greater than 130 kg/m³ or no greater than 125 kg/m³ or no greater than 120 kg/m³ or no greater than 115 kg/m³ or no greater than 110 kg/m³. It will be appreciated that the density may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 50 kg/m³, and not greater than 165 kg/m³ or at least 52 kg/m³ and not greater than 115 kg/m³.

In an embodiment, the abrasive article 100 can have a coat weight that includes the weight of the interlayer 110 and the abrasive layer 101. The abrasive article can have a particular coat weight that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the coat weight can be at 15 g/m² or at least 16 g/m² or at least 17 g/m² or at least 18 g/m² or at least 19 g/m² or at least 20 g/m² or at least 21 g/m² or at least 22 g/m² or at least 23 g/m² or at least 24 g/m² or at least 25 g/m² or at least 30 g/m² or at least 35 g/m² or at least 40 g/m² or at least 50 g/m² or at least 60 g/m². In an embodiment, the coat weight can be no greater than no greater than 100 g/m² or no greater than 75 g/m² or no greater than 70 g/m² or no greater than 65 g/m² or no greater than 60 g/m² or no greater than 55 g/m² or no greater than 50 g/m² or no greater than 45 g/m² or no greater than 40 g/m² or no greater than 35 g/m² or no greater than 30 g/m². It will be appreciated that the coat weight may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 17 g/m², and not greater than 70 g/m² or at least 20 g/m² and not greater than 65 g/m².

The abrasive article can further include a tie layer 120. In an embodiment, the tie layer 120 may underlie the abrasive layer 101. In an embodiment, the tie layer may underlie the interlayer 110. In an embodiment, the tie layer may be adjacent to the interlayer 110. In an embodiment, the tie layer may overlay the backing 120. In an embodiment, the tie layer may be adjacent to the backing 120. The tie layer may include a particular material that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the tic layer can comprise a radiation curable binder. In a particular embodiment, the tie layer can comprise any epoxy, an acrylate, a methacrylate, polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), isocyanate, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, UV curable resins, or combinations thereof. In an embodiment, the tie layer can include silane. In an embodiment, the tie layer can include a photoinitiator.

In an embodiment, the tie layer may have a particular elastic modulus that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the tie coat can have an elastic modulus of at least 1×10⁴ Pa or at least 5×10⁴ Pa or at least 1×10⁵ Pa or at least 5×10⁵ Pa or at least 1×10⁶ Pa or at least 5×10⁶ Pa or at least 1×10⁷ Pa or at least 5×10⁷ Pa or at least 1×10⁸ Pa. In an embodiment, the tie coat can have an elastic modulus of no greater than 5×10⁹ Pa or no greater than 3×10⁹ Pa or no greater than 1×10⁹ Pa or no greater than 5×10⁸ Pa or no greater than 2×10⁸ Pa or no greater than 1×10⁸ Pa or no greater than 5×10⁷ Pa or no greater than 1×10⁷ Pa or no greater than 5×10⁶ Pa or no greater than 1×10⁶ Pa. It will be appreciated that the elastic modulus of the tie coat may be between any of the minimum and maximum values noted above, including for example, but not limited to 1×10⁴ to 1×10⁶ Pa or 1×10⁸ to 3×10⁹ Pa.

In an embodiment the abrasive article may have a particular combination of shaped structure height, tie coat elastic modulus, interlayer height, and coating weight of the interlayer and shaped structures.

When the abrasive article has a tie coat with a relatively low modulus (less than 1×10⁶ Pa; or 1×10⁴ to 1×10⁶ Pa; or 6×10⁵ to 7×10⁵) and small structure height (15-25 microns), the abrasive article may have either:

• • a) A coat weight of at least 25 g/m² or at least 30 g/m² or at least 35 g/m² or at least 40 g/m² or at least 50 g/m² or at least 60 g/m²; or
  • b) An ILT_ave of at least 7 microns or at least 7.5 microns or at least 8 microns or at least 8.5 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns.

When the abrasive article has a tie coat with a relatively low modulus (less than 1×10⁶ Pa; or 1×10⁴ to 1×10⁶ Pa; or 6×10⁵ to 7×10⁵) and medium structure height (25-35 microns), the abrasive article may have either:

• • a) A coat weight of at least 25 g/m² or at least 30 g/m² or at least 35 g/m² or at least 40 g/m²; or
  • b) An ILT_ave of at least 14 microns.

When the abrasive article has a tie coat with a relatively low modulus (at least 1×10⁸ Pa; or 1×10⁸ to 3×10⁹ Pa; or 1×10⁸ to 2×10⁸) and small structure height (15-25 microns), the abrasive article may have either:

• • a) A coat weight of at least 17 g/m² and not greater than 75 g/m² or at least 20 g/m² and not greater than 40 g/m² or at least 25 g/m² and not greater than 35 g/m²; or
  • b) An ILT_ave of at least 6 microns and not greater than 17 microns or at least 7 microns and not greater than 10 microns.

When the abrasive article has a tie coat with a relatively low modulus (at least 1×10⁸ Pa; or 1×10⁸ to 3×10⁹ Pa; or 1×10⁸ to 2×10⁸) and medium structure height (25-35 microns), the abrasive article may have either:

• • a) A coat weight of at least 17 g/m² and not greater than 75 g/m² or at least 20 g/m² and not greater than 40 g/m² or at least 20 g/m² and not greater than 30 g/m²; or
  • b) An ILT_ave of at least 5 microns and not greater than 11 microns or at least 7 microns and not greater than 10 microns.

When the abrasive article has a tie coat with a relatively low modulus (at least 1×10⁸ Pa; or 1×10⁸ to 3×10⁹ Pa; or 1×10⁸ to 2×10⁸) and large structure height (35-45 microns), the abrasive article may have either:

• • a) A coat weight of at least 60 g/m²; or
  • b) An ILT_ave of at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns.

The abrasive article can further include a reinforcing layer. In an embodiment, the reinforcement layer may overly the backing or underlie the backing. In an embodiment, the reinforcing layer may be adjacent to the backing. In an embodiment, the reinforcing layer may include a particular material that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the reinforcing layer may include a polymeric film, PET liner, paper, glass mesh, synthetic mesh, an organic coating, tape, glue, or a combination thereof.

The abrasive article can further include an attachment layer. In an embodiment, the attachment layer may underlie the backing. In an embodiment, the reinforcing layer may be adjacent to the backing. In an embodiment, the attachment layer may include a particular material that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the reinforcing layer may include a polymeric film, PET liner, paper, glass mesh, synthetic mesh, organic coating, loop fastener, Velcro, tape, glue, a mechanical fastener or a combination thereof.

The aforementioned abrasive article may be used to polish workpieces including acrylic, paint, isocyanate, urethanes, polymeric layers, coatings, and particularly, automotive clear coats. The abrasive may be able to polish the workpiece to a particular surface finish (Rz) such as less than 40 μin or less than 39 μin or less than 38 μin or less than 37 μin or less than 36 μin or less than 35 μin or less than 34 μin or less than 33 μin or less than 32 μin or less than 31 μin or less than 30 μin or less than 29 μin or less than 28 μin or less than 27 μin or less than 26 μin or less than 25 μin or at least 1 μin.

The aforementioned abrasive article may be used as part of a system of abrasive articles for polishing workpieces. The abrasive system can also include a second abrasive article, intended to be used before the abrasive article described in the paragraphs above.

In an embodiment, the second abrasive article can include a second backing, and a second abrasive layer overlying the second backing. The second abrasive layer can include abrasive particles and a binder.

In an embodiment, the second backing can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive system. In an embodiment, the second backing can comprise a polymeric film (for example, a primed film), such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), polyester film (e.g., polyethylene terephthalate), polyamide film, or cellulose ester film; metal foil; mesh; foam (e.g., natural sponge material or polyurethane foam or polyester foam or polyolefin foam or PVC foam or silicone foam); cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; nonwoven materials; a combination thereof. In a more particular embodiment, the second backing may comprise a polymeric film.

In an embodiment, the second abrasive particles can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive system. In an embodiment, the second abrasive particles can comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof. In a particular embodiment, the second abrasive particles can comprise or consist of alumina. In an embodiment, the abrasive particles can include a silane coating.

In an embodiment, the second abrasive particles may have a particular median particle size that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the second abrasive particles can be larger than the abrasive particles 106. In an embodiment, the second abrasive particles can have a median particle size of 9-12.5 microns.

The abrasive system can further include a polishing slurry. The polishing slurry may include a third plurality of abrasive particles. In an embodiment, the second abrasive particles can have a particular composition that may facilitate improved performance and/or manufacturing of the abrasive system. In an embodiment, the third plurality of abrasive particles can comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof. In a particular embodiment, the third plurality of abrasive particles can comprise or consist of alumina. In an embodiment, the abrasive particles can include a silane coating. The third plurality of abrasive particles can be finer than the abrasive particles 106.

Embodiments

Embodiment 1. An abrasive article comprising:

• • a backing,
  • an abrasive layer overlying the backing,
    • the abrasive layer comprising a plurality of shaped structures comprising abrasive particles and a binder,
  • an interlayer between the backing and the abrasive layer, the interlayer comprising at least one of the following:
    • an ILT_ave of at least 4 microns,
    • an ILT_max of at least 5 microns, or
    • an ILT_min of at least 3 microns.

Embodiment 2. The abrasive article of embodiment 1, wherein the interlayer has an ILT_ave of at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns or at least 8.5 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns.

Embodiment 3. The abrasive article of embodiment 1, wherein the interlayer has an ILT_ave of no greater than 40 microns or no greater than 35 microns or no greater than 30 microns or no greater than 25 microns or no greater than 20 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns.

Embodiment 4. The abrasive article of embodiment 1, wherein the interlayer has an ILT max of at least 5 microns or at least 6 microns or at least 7 microns or at least 8 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns.

Embodiment 5. The abrasive article of embodiment 1, wherein the interlayer has an ILT_max of no greater than 20 microns or no greater than 19 microns or no greater than 18 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns.

Embodiment 6. The abrasive article of embodiment 1, wherein the interlayer has an ILT_min of at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns.

Embodiment 7. The abrasive article of embodiment 1, wherein the interlayer has an ILT_min of no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns.

Embodiment 8. The abrasive article of embodiment 1, wherein the interlayer has an ILT₅₀ of at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns or at least microns or at least 8.5 microns or at least 9 microns or at least 9.5 microns or at least 10 microns or at least 10.5 microns or at least 11 microns or at least 11.5 microns or at least 12 microns or at least 12.5 microns or at least 13 microns.

Embodiment 9. The abrasive article of embodiment 1, wherein the interlayer has an ILT₅₀ of no greater than 20 microns or no greater than 19 microns or no greater than 18 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns.

Embodiment 10. The abrasive article of embodiment 1, wherein the interlayer has an ILT₈₀ of at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns or at least microns or at least 8.5 microns or at least 9 microns or at least 9.5 microns or at least 10 microns or at least 10.5 microns or at least 11 microns or at least 11.5 microns or at least 12 microns or at least 12.5 microns or at least 13 microns.

Embodiment 11. The abrasive article of embodiment 1, wherein the interlayer has an ILT₈₀ of no greater than 20 microns or no greater than 19 microns or no greater than 18 microns or no greater than 17 microns or no greater than 16 microns or no greater than 15 microns or no greater than 14 microns or no greater than 13 microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns.

Embodiment 12. The abrasive article of embodiment 1, wherein the interlayer has an ILT_diff of at least 0.5 microns or at least 1 micron or at least 1.5 microns or at least 2 microns or at least 2.5 microns or at least 3 microns or at least 3.5 microns or at least 4 microns or at least 4.5 microns or at least 5 microns or at least 5.5 microns or at least 6 microns or at least 6.5 microns or at least 7 microns or at least 7.5 microns or at least 8 microns.

Embodiment 13. The abrasive article of embodiment 1, wherein the interlayer has an ILT_diff of no greater than 13 microns or no greater than 12 microns or no greater than 11 microns or no greater than 10 microns or no greater than 9 microns or no greater than 8 microns or no greater than 7 microns or no greater than 6 microns.

Embodiment 14. The abrasive article of embodiment 1, wherein the shaped structures comprise pyramidal shapes.

Embodiment 15. The abrasive article of embodiment 1, wherein the shaped structures comprise rectangular pyramids.

Embodiment 16. The abrasive article of embodiment 1, wherein the shaped structures comprise a height measured perpendicular to the backing.

Embodiment 17. The abrasive article of embodiment 1, wherein the shaped structures comprise a length and a width measured parallel to the backing, wherein the length is greater than or equal to the width.

Embodiment 18. The abrasive article of embodiment 1, wherein the shaped structures comprise a height of at least 5 microns or at least 6 microns or at least 7 microns or at least 8 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns or at least 15 microns or at least 16 microns or at least 17 microns or at least 18 microns or at least 19 microns or at least 20 microns or at least 21 microns or at least 22 microns or at least 23 microns or at least 24 microns or at least 25 microns or at least 26 microns or at least 27 microns or at least 28 microns or at least 29 microns or at least 30 microns or at least 31 microns or at least 32 microns or at least 33 microns or at least 34 microns or at least 35 microns.

Embodiment 19. The abrasive article of embodiment 1, wherein the shaped structures comprise a height of no greater than 50 microns or no greater than 49 microns or no greater than 48 microns or no greater than 47 microns or no greater than 46 microns or no greater than 45 microns or no greater than 44 microns or no greater than 43 microns or no greater than 42 microns or no greater than 41 microns or no greater than 40 microns or no greater than 39 microns or no greater than 38 microns or no greater than 37 microns or no greater than 36 microns or no greater than 35 microns or no greater than 34 microns or no greater than 33 microns or no greater than 32 microns or no greater than 31 microns or no greater than 30 microns or no greater than 29 microns or no greater than 28 microns or no greater than 27 microns or no greater than 26 microns or no greater than 25 microns.

Embodiment 20. The abrasive article of embodiment 1, wherein the shaped structures comprise a length of at least 100 microns or at least 110 microns or at least 120 microns or at least 130 microns or at least 140 microns or at least 150 microns or at least 160 microns or at least 170 microns or at least 180 microns or at least 190 microns or at least 200 microns.

Embodiment 21. The abrasive article of embodiment 1, wherein the shaped structures comprise a length of no greater than 400 microns or no greater than 375 microns or no greater than 350 microns or no greater than 325 microns or no greater than 300 microns or no greater than 275 microns or no greater than 250 microns.

Embodiment 22. The abrasive article of embodiment 1, wherein the shaped structures comprise a width of at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns or at least 15 microns or at least 16 microns or at least 17 microns or at least 18 microns or at least 19 microns or at least 20 microns.

Embodiment 23. The abrasive article of embodiment 1, wherein the shaped structures comprise a width of no greater than 60 microns or no greater than 58 microns or no greater than 56 microns or no greater than 54 microns or no greater than 52 microns or no greater than 50 microns or no greater than 48 microns or no greater than 46 microns or no greater than 44 microns or no greater than 42 microns or no greater than 40 microns or no greater than 40 microns.

Embodiment 24. The abrasive article of embodiment 1, wherein the abrasive article comprises an average interlayer thickness to average structure height ratio of at least 1:10 or at least 1:5 or at least 1:4.5 or at least 1:4 or at least 1:3.5 or at least 1:3 or at least 1:2.5 or at least 1:2 or at least 1:1.5 or at least 1:1 or at least 1.5:1 or at least 2:1 or at least 2.5:1 or at least 3:1 or at least 3.5:1 or at least 4:1 or at least 4.5:1 or at least 5:1.

Embodiment 25. The abrasive article of embodiment 1, wherein the abrasive article comprises an average interlayer thickness to average structure height ratio of no greater than 5:1 or no greater than 4.5:1 or no greater than 4:1 or no greater than 3.5:1 or no greater than 3:1 or no greater than 2.5:1 or no greater than 2:1 or no greater than 1.5:1 or no greater than 1:1 or no greater than 1:1.5 or no greater than 1:2 or no greater than 1:2.5 or no greater than 1:3 or no greater than 1:3.5 or no greater than 1:4 or no greater than 1:4.5 or no greater than 1:5.

Embodiment 26. The abrasive article of embodiment 1, wherein the abrasive layer comprises a shaped structure density of at least 100 lpi_w or at least 150 lpi_w or at least 200 lpi_w or at least 250 lpi_w or at least 300 lpi_w or at least 350 lpi_w or at least 400 lpi_w or at least 450 lpi_w.

Embodiment 27. The abrasive article of embodiment 1, wherein the abrasive layer comprises a shaped structure density of no greater than 800 lpi_w or no greater than 775 lpi_w or no greater than 750 lpi_w or no greater than 625 lpi_w or no greater than 700 lpi_w or no greater than 675 lpi_w or no greater than 650 lpi_w or no greater than 625 lpi_w or no greater than 600 lpi_w or no greater than 575 lpi_w or no greater than 550 lpi_w or no greater than 525 lpi_w or no greater than 500 lpi_w or no greater than 475 lpi_w.

Embodiment 28. The abrasive article of embodiment 1, wherein the abrasive layer comprises a shaped structure density of at least 40 lpi_l or at least 45 lpi_l or at least 50 lpi_l or at least 55 lpi_l or at least 60 lpi_l or at least 65 lpi_l or at least 70 lpi_l or at least 75 lpi_l or at least 80 lpi_l or at least 85 lpi_l.

Embodiment 29. The abrasive article of embodiment 1, wherein the abrasive layer comprises a shaped structure density of no greater than 200 lpi_l or no greater than 190 lpi_l or no greater than 180 lpi_l or no greater than 170 lpi_l or no greater than 160 lpi_l or no greater than 150 lpi_l or no greater than 140 lpi_l or no greater than 130 lpi_l or no greater than 120 lpi_l or no greater than 110 lpi_l or no greater than 100 lpi_l.

Embodiment 30. The abrasive article of embodiment 1, wherein the abrasive layer comprises a shaped structure density of 30-100 shaped structures per mm².

Embodiment 31. The abrasive article of embodiment 30, wherein the shaped structures comprise pyramids wherein the length does not equal the width.

Embodiment 32. The abrasive article of embodiment 1, wherein the abrasive layer comprises a shaped structure density of 100-450 shaped structures per mm².

Embodiment 33. The abrasive article of embodiment 32, wherein the shaped structures comprise pyramids wherein the length is equal to the width.

Embodiment 34. The abrasive article of embodiment 1, wherein the abrasive particles comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof.

Embodiment 35. The abrasive article of embodiment 1, wherein the abrasive particles comprise silicon carbide.

Embodiment 36. The abrasive article of embodiment 1, wherein the abrasive particles comprise a median particle size of at least 1 micron or at least 2 microns or at least 3 microns or at least 4 microns or at least 5 microns.

Embodiment 37. The abrasive article of embodiment 1, wherein the abrasive particles comprise a median particle size of no greater than 20 microns or no greater than 18 microns or no greater than 16 microns or no greater than 14 microns or no greater than 12 microns or no greater than 10 microns or no greater than 8 microns.

Embodiment 38. The abrasive article of embodiment 1, wherein the abrasive particles comprise a silane coating.

Embodiment 39. The abrasive article of embodiment 1, wherein the binder comprises a radiation curable binder.

Embodiment 40. The abrasive article of embodiment 1, wherein the binder comprises any epoxy, an acrylate, a methacrylate, polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), isocyanate, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, UV curable resins, or combinations thereof.

Embodiment 41. The abrasive article of embodiment 1, wherein the binder comprises a photoinitiator.

Embodiment 42. The abrasive article of embodiment 1, wherein the binder comprises silane.

Embodiment 43. The abrasive article of embodiment 1, wherein the binder comprises an additive comprising solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators, agents for influencing the fluidity of the dispersion, grinding aids, fillers, extenders, defoamers, surfactants, or combinations thereof.

Embodiment 44. The abrasive article of embodiment 1, wherein the interlayer comprises interlayer particles and an interlayer binder.

Embodiment 45. The abrasive article of embodiment 44, wherein the interlayer has the same composition as the abrasive layer.

Embodiment 46. The abrasive article of embodiment 44, wherein the interlayer has a different composition than the abrasive layer.

Embodiment 47. The abrasive article of embodiment 44, wherein the interlayer particles comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof.

Embodiment 48. The abrasive article of embodiment 44, wherein the interlayer particles comprise silicon carbide.

Embodiment 49. The abrasive article of embodiment 44, wherein the interlayer particles comprise a silane coating.

Embodiment 50. The abrasive article of embodiment 44, wherein the interlayer particles are the same as the abrasive particles.

Embodiment 51. The abrasive article of embodiment 44, wherein the interlayer particles are different from abrasive particles.

Embodiment 52. The abrasive article of embodiment 44, wherein the interlayer binder comprises a radiation curable binder.

Embodiment 53. The abrasive article of embodiment 44, wherein the interlayer binder comprises any epoxy, an acrylate, a methacrylate, polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, UV curable resins, or combinations thereof.

Embodiment 54. The abrasive article of embodiment 44, wherein the interlayer binder comprises a photoinitiator.

Embodiment 55. The abrasive article of embodiment 44, wherein the interlayer binder comprises silane.

Embodiment 56. The abrasive article of embodiment 44, wherein the interlayer binder comprises an additive comprising solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators, agents for influencing the fluidity of the dispersion, grinding aids, fillers, extenders, defoamers, surfactants, or combinations thereof.

Embodiment 57. The abrasive article of embodiment 44, wherein the interlayer binder is the same as the abrasive binder.

Embodiment 58. The abrasive article of embodiment 44, wherein the interlayer binder is different from abrasive binder.

Embodiment 59. The abrasive article of embodiment 1, wherein the backing comprises a polymeric film (for example, a primed film), such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), polyester film (e.g., polyethylene terephthalate), polyamide film, or cellulose ester film; metal foil; mesh; foam (e.g., natural sponge material or polyurethane foam or polyester foam or polyolefin foam or PVC foam or silicone foam); cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; nonwoven materials; a combination thereof.

Embodiment 60. The abrasive article of embodiment 1, wherein the backing comprises foam.

Embodiment 61. The abrasive article of embodiment 1, wherein the backing comprises polyurethane foam.

Embodiment 62. The abrasive article of embodiment 1, wherein the abrasive article comprises a coat weight, wherein the coat weight comprises the weight of the interlayer and the abrasive layer, wherein the coat weight is at least 15 g/m² or at least 16 g/m² or at least 17 g/m² or at least 18 g/m² or at least 19 g/m² or at least 20 g/m² or at least 21 g/m² or at least 22 g/m² or at least 23 g/m² or at least 24 g/m² or at least 25 g/m² or at least 30 g/m² or at least 35 g/m² or at least 40 g/m² or at least 50 g/m² or at least 60 g/m².

Embodiment 63. The abrasive article of embodiment 1, wherein the abrasive article comprises a coat weight, wherein the coat weight comprises the weight of the interlayer and the abrasive layer, wherein the coat weight is no greater than 100 g/m² or no greater than 75 g/m² or no greater than 70 g/m² or no greater than 65 g/m² or no greater than 60 g/m² or no greater than 55 g/m² or no greater than 50 g/m² or no greater than 45 g/m² or no greater than 40 g/m² or no greater than 35 g/m² or no greater than 30 g/m².

Embodiment 64. The abrasive article of embodiment 1, further comprising a tie layer underlying the inter layer.

Embodiment 65. The abrasive article of embodiment 64, wherein the tie layer is adjacent the interlayer layer.

Embodiment 66. The abrasive article of embodiment 64, wherein the tie layer is overlying the backing.

Embodiment 67. The abrasive article of embodiment 64, wherein the tie layer is adjacent the backing.

Embodiment 68. The abrasive article of embodiment 64, wherein the tie layer comprises a radiation curable binder.

Embodiment 69. The abrasive article of embodiment 64, wherein the tie layer comprises any epoxy, an acrylate, a methacrylate, polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), isocyanate, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, UV curable resins, or combinations thereof.

Embodiment 70. The abrasive article of embodiment 64, wherein the tie layer comprises a photoinitiator.

Embodiment 71. The abrasive article of embodiment 64, wherein the tie layer comprises an elastic modulus of at least 1×10⁴ Pa or at least 5×10⁴ Pa or at least 1×10⁵ Pa or at least 5×10⁵ Pa or at least 1×10⁶ Pa or at least 5×10⁶ Pa or at least 1×10⁷ Pa or at least 5×10⁷ Pa or at least 1×10⁸ Pa.

Embodiment 72. The abrasive article of embodiment 64, wherein the tie layer comprises an elastic modulus of no greater than 5×10⁹ Pa or no greater than 3×10⁹ Pa or no greater than 1×10⁹ Pa or no greater than 5×10⁸ Pa or no greater than 2×10⁸ Pa or no greater than 1×10⁸ Pa or no greater than 5×10⁷ Pa or no greater than 1×10⁷ Pa or no greater than 5×10⁶ Pa or no greater than 1×10⁶ Pa.

Embodiment 73. The abrasive article of embodiment 64, the tie layer comprises:

• • an elastic modulus of:
    • 1) less than 1×10⁶ Pa;
    • 2) 1×10⁴ to 1×10⁶ Pa; or
    • 3) 6×10⁵ to 7×10⁵;
  • a shaped structure height of 15-25 microns;
  • and either:
  • a) A coat weight of at least 25 g/m² or at least 30 g/m² or at least 35 g/m² or at least 40 g/m² or at least 50 g/m² or at least 60 g/m²; or
  • b) An ILT_ave of at least 7 microns or at least 7.5 microns or at least 8 microns or at least 8.5 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns.

Embodiment 74. The abrasive article of embodiment 64, the tie layer comprises:

• • an elastic modulus of:
    • 1) less than 1×10⁶ Pa;
    • 2) 1×10⁴ to 1×10⁶ Pa; or
    • 3) 6×10⁵ to 7×10⁵;
  • a shaped structure height of 25-35 microns;
  • and either:
    • a) A coat weight of at least 25 g/m² or at least 30 g/m² or at least 35 g/m² or at least 40 g/m²; or
    • b) An ILT_ave of at least 14 microns.

Embodiment 75. The abrasive article of embodiment 64, the tie layer comprises:

• • an elastic modulus of:
    • 1) at least 1×10⁸ Pa;
    • 2) 1×10⁸ to 3×10⁹ Pa; or
    • 3) 1×10⁸ to 2×10⁸;
  • a shaped structure height of 15-25 microns;
  • and either:
    • a) A coat weight of at least 17 g/m² and not greater than 75 g/m² or at least 20 g/m² and not greater than 40 g/m² or at least 25 g/m² and not greater than 35 g/m².
    • b) An ILT_ave of at least 6 microns and not greater than 17 microns or at least 7 microns and not greater than 10 microns.

Embodiment 76. The abrasive article of embodiment 64, the tie layer comprises:

• • an elastic modulus of:
    • 1) at least 1×10⁸ Pa;
    • 2) 1×10⁸ to 3×10⁹ Pa; or
    • 3) 1×10⁸ to 2×10⁸;
  • a shaped structure height of 25-35 microns;
  • and either:
    • a) A coat weight of at least 17 g/m² and not greater than 75 g/m² or at least 20 g/m² and not greater than 40 g/m² or at least 20 g/m² and not greater than 30 g/m².
    • b) An ILT_ave of at least 5 microns and not greater than 11 microns or at least 7 microns and not greater than 10 microns.

Embodiment 77. The abrasive article of embodiment 64, the tie layer comprises:

• • an elastic modulus of:
    • 1) at least 1×10⁸ Pa;
    • 2) 1×10⁸ to 3×10⁹ Pa; or
    • 3) 1×10⁸ to 2×10⁸;
  • a shaped structure height of 35-45 microns;
  • and either:
    • a) A coat weight of at least 60 g/m².
    • b) An ILT_ave of at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns.

Embodiment 78. The abrasive article of embodiment 1, further comprising a reinforcement layer.

Embodiment 79. The abrasive article of embodiment 78, wherein the reinforcement layer is overlying the backing.

Embodiment 80. The abrasive article of embodiment 78, wherein the reinforcement layer is underlying the backing.

Embodiment 81. The abrasive article of embodiment 78, wherein the reinforcement layer is adjacent to the backing.

Embodiment 82. The abrasive article of embodiment 78, wherein the reinforcement layer is a polymeric film, a PET liner, paper, glass mesh, synthetic mesh, an organic coating, tape, glue, or a combination thereof.

Embodiment 83. The abrasive article of embodiment 1, further comprising an attachment layer underlying the backing.

Embodiment 84. The abrasive article of embodiment 83, wherein the attachment layer comprises a polymeric film, a PET liner, paper, glass mesh, synthetic mesh, an organic coating, a loop fastener, Velcro, tape, glue, a mechanical fastener, or a combination thereof.

Embodiment 85. A method of making an abrasive article comprising:

• • providing a backing;
  • depositing an interlayer and abrasive layer overlying the backing, the abrasive layer comprising a plurality of shaped structures comprising abrasive particles and a binder,
  • an interlayer between the backing and the abrasive layer, the interlayer comprising at least one of the following:
    • an ILT_ave of at least 4 microns,
    • an ILT_max of at least 5 microns, or
    • an ILT_min of at least 3 microns.

Embodiment 86. The method of embodiment 85, further comprising depositing a tie layer on the backing, before depositing the interlayer and the abrasive layer.

Embodiment 87. The method of embodiment 86, wherein the interlayer and abrasive layer are deposited directly onto the tie layer.

Embodiment 88. The method of embodiment 86, further comprising curing the tie layer.

Embodiment 89. The method of embodiment 85, further comprising curing the interlayer and abrasive layer.

Embodiment 90. The method of embodiment 85, further comprising depositing an abrasive slurry into a mold to form the abrasive layer and the interlayer.

Embodiment 91. The method of embodiment 90, wherein the abrasive slurry is deposited with a knife blade coater.

Embodiment 92. The method of embodiment 91, wherein the abrasive slurry is deposited with a knife blade coater having a knife gap of 0 mil.

Embodiment 93. The method of embodiment 91, wherein the abrasive slurry is deposited with a knife blade coater having a knife gap of no greater than 10 mil or no greater than 8 mil or no greater than 6 mil or no greater than 5 mil or no greater than 4.5 mil or no greater than 4 mil or no greater than 3.5 mil or no greater than 3 mil or no greater than 2.5 mil.

Embodiment 94. The method of embodiment 91, wherein the abrasive slurry is deposited with a knife blade coater having a knife gap of at least 0 mils or at least 0.01 mil or at least 0.1 mil or at least 0.5 mil or at least 1 mil.

Embodiment 95. The method of embodiment 85, wherein the abrasive article comprises the abrasive article of any one of embodiments 1 to 84.

Embodiment 96. A method of using the abrasive article of any one of embodiments 1 to 84, to polish a workpiece, wherein the workpiece comprises an automotive clear coat, acrylic, paint, isocyanate, urethanes, polymeric layers, coatings.

Embodiment 97. The method of embodiment 96, wherein the workpiece has a surface finish (Rz) of less than 40 μin or less than 39 μin or less than 38 μin or less than 37 μin or less than 36 μin or less than 35 μin or less than 34 μin or less than 33 μin or less than 32 μin or less than 31 μin or less than 30 μin or less than 29 μin or less than 28 μin or less than 27 μin or less than 26 μin or less than 25 μin.

Embodiment 98. The method of embodiment 96, wherein the workpiece has a surface finish of at least 1 μin.

Embodiment 99. The method of embodiment 96, wherein the method further comprises abrading the workpiece with a second abrasive article.

Embodiment 100. The method of embodiment 99, wherein the second abrasive article comprises a second backing,

• • and a second abrasive layer overlying the second backing,
  • the second abrasive layer comprising abrasive particles and a binder.

Embodiment 101. The method of embodiment 99, wherein the second backing comprises a polymeric film (for example, a primed film), such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), polyester film (e.g., polyethylene terephthalate), polyamide film, or cellulose ester film; metal foil; mesh; foam (e.g., natural sponge material or polyurethane foam); cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; nonwoven materials; a combination thereof; or a treated version thereof.

Embodiment 102. The method of embodiment 99, wherein the second backing comprises a polymeric film.

Embodiment 103. The method of embodiment 99, wherein the second plurality of abrasive particles comprises silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof.

Embodiment 104. The method of embodiment 99, wherein the second plurality of abrasive particles comprises alumina.

Embodiment 105. The method of embodiment 99, wherein the second plurality of abrasive particles comprises a median particle size of 9-12.5 microns.

Embodiment 106. The method of embodiment 99, wherein the second plurality of abrasive particles comprises a larger median particle size than the first plurality of abrasive particles.

Embodiment 107. The method of any one of embodiments 96 to 106, wherein the abrading with the second abrasive article step is before polishing with the abrasive article.

Embodiment 108. The method of any one of embodiments 96 to 107, further including polishing the workpiece with a polishing slurry after polishing with the abrasive article, wherein the polishing slurry comprises a third plurality abrasive particles.

Embodiment 109. The method of embodiment 108, wherein the third plurality of abrasive particles comprise alumina.

Embodiment 110. The method of embodiment 108, wherein the third plurality of abrasive particles comprise a third median particle size smaller than the first median particle size.

Examples

Samples 1-3 as shown in Table 3 were prepared according to the process below having the composition in Table 1. Polyurethane foam substrates were prepared by applying a thin layer of the tie coat formulation in Table 1 to the substrate surface. The tie coat had an elastic modulus between 1×10⁸ Pa and 2×10⁸ Pa. About 100 g/m² of this layer was applied using a reverse roll coating method and the layer was cured using a 395 nm UV LED bulb.

TABLE 1
Description        Wt. %
Acrylic Oligomer   58-62
UV-curable Acrylic 20-22
Monomer 1
UV-curable Acrylic 15-16
Monomer 2
Photoinitiator     2-3

An abrasive slurry is prepared according to the formulation in Table 2.

TABLE 2
Description              Wt. %
UV-curable Acrylic       18-22
Monomer 1
UV-curable Acrylic       12-14
Monomer 2
Photoinitiator           0.5-1.5
Dispersant               0.5-1.5
Silane Adhesion Promoter 2-3
SiC Grain                60-65

The abrasive formulation 401 was deposited into a mold (a thermoplastic sheet) 410, containing a negative impression of the desired shaped abrasive structures. This abrasive slurry 401 was deposited on the mold using a knife blade coater 420 with a gap of 0-3 mil or a squeegee 421 depending on the sample. Example illustrations of this process can be seen in FIGS. 4a and 4b. The slurry 401 is spread throughout the mold 410. The previously prepared foam substrate was then placed on top of the abrasive slurry so that the tie coat contacts the abrasive slurry. The foam substrate and mold were compressed to a set thickness, roughly half the thickness of the foam, then cured using a 395 nm UV LED bulb at a speed of 20 ft./minute. The mold was then peeled from the foam substrate, the abrasive layer now attached to the tie layer on the foam substrate. A loop fastener was laminated to the back of the foam substrate and 5-inch diameter discs were punched out for testing.

Interlayer thickness (ILT) is characterized according to the following process. Cross sections of the abrasive article parallel to the width dimension of the shaped figures were prepared. ILT measurements were taken in the corner of shaped structures where the local minima occur. 5-15 measurements were taken on each sample. ILT_min is the lowest ILT that is taken on an abrasive article. ILT_max is the highest ILT measurement taken on an abrasive article. ILT_ave is the mean ILT measurement taken on an abrasive article.

	TABLE 3
	Surface
	Finish,
	Shape		Knife	Interlayer	Coat	Material	Rz @
	height	Knife	Gap	Thickness (μ)	weight	removed	90 s
Sample	(μ)	Type	(mil)	Min	Max	Ave	(g/m2)	(g)	(μin)
1S	20	Squeegee	N/A	2.59	7.78	5.54	16.87	0.23	36.93
1M	20	Knife	0	6.53	11.2	8.09	29.72	0.26	20.57
		Blade
		coater
1L	20	Knife	2	5.87	36.3	17.91	89.54	0.18	26.40
		Blade
		coater
2S	30	Squeegee	N/A	4.1	5.4	4.93	15.48	0.36	29.50
2M	30	Knife	0	6.7	12.33	8.66	27.64	0.41	22.93
		Blade
		coater
2L	30	Knife	2	6.5	17.29	11.10	77.18	0.21	22.60
		Blade
		coater
3S	40	Knife	0	2.59	4.87	3.76	32.65	0.25	48.20
		Blade
		coater
3M	40	Knife	2	8.68	17.6	11.08	57.59	0.25	25.20
		Blade
		coater
3L	40	Knife	3	8.3	26.4	15.32	76.83	0.30	26.33
		Blade
		coater

All samples were used to polish a fresh aftermarket clear coat panel (Spies Hecker 8046; 6″×24″). Before testing, the panels were sanded with Q175 1500 for 30 seconds and the starting surface finish was recorded. Panels were sprayed with water using a spray bottle and then polished using the above-described samples and a 5″ Hutchins DA sander with 3/32″ orbit in 3 30-second intervals of approximately 12 passes/30 seconds. The panel is weighed after each interval to track the amount of material removed. The surface finish is measured at 3 spots across the panel and averaged.

Samples 4 and 5 as shown in Table 5 below were prepared according to the process above having the tie coat with the composition detailed below in Table 4 having an elastic modulus of 6×10⁵ Pa-7×10⁵ Pa. The abrasive slurry in Table 3 was used for samples 4 and 5.

TABLE 4
Material           Wt. %
UV-curable acrylic 90-95
monomers
Photoinitiator     2-5
Rheology modifier  2-5

Samples 4 and 5 and their ILT thickness and polishing performance are evaluated according to the same methods used for samples 1-3 above. Results can be seen below in Table 5.

TABLE 5
					Surface
	Shape	Interlayer	Coat	Material	Finish,
	height	Thickness (μ)	weight	removed	Rz @
Sample	(μ)	Ave	(g/m2)	(g)	90s (μin)
4S	20	2.99	10.16	0.33	28.33
4M	20	6.84	25.49	0.38	35.43
4L	20		68.06	0.59	27.33
5S	30	5.39	8.68	0.32	40.94
5M	30	13.55	25	0.33	51.55
5L	30		43.81	0.69	30.10

The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, that fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents and shall not be restricted or limited by the foregoing detailed description.

The Abstract of the Disclosure is provided to comply with Patent Law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure.

This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.

Claims

1. An abrasive article comprising: a backing,an abrasive layer overlying the backing, the abrasive layer comprising a plurality of shaped structures comprising abrasive particles and a binder,an interlayer between the backing and the abrasive layer, the interlayer comprising at least one of the following: an ILTave of at least 4 microns,an ILTmax of at least 5 microns, oran ILTmin of at least 3 microns.

2. The abrasive article of claim 1, wherein the interlayer has an ILTave of at least 4 microns.

3. The abrasive article of claim 1, wherein the interlayer has an ILTave of no greater than 40 microns.

4. The abrasive article of claim 1, wherein the shaped structures comprise a height of at least 5 microns.

5. The abrasive article of claim 1, wherein the shaped structures comprise a height of no greater than 50 microns.

6. The abrasive article of claim 1, wherein the abrasive article comprises an average interlayer thickness to average structure height ratio of at least 1:10 and no greater than 5:1.

7. The abrasive article of claim 1, wherein the abrasive particles comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof.

7. The abrasive article of claim 1, wherein the backing comprises a polymeric film (for example, a primed film), such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), polyester film (e.g., polyethylene terephthalate), polyamide film, or cellulose ester film; metal foil; mesh; foam (e.g., natural sponge material or polyurethane foam or polyester foam or polyolefin foam or PVC foam or silicone foam); cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; nonwoven materials; a combination thereof.

8. The abrasive article of claim 1, wherein the backing comprises foam.

9. The abrasive article of claim 1, wherein the backing comprises polyurethane foam.

10. The abrasive article of claim 1, wherein the abrasive article comprises a coat weight, wherein the coat weight comprises the weight of the interlayer and the abrasive layer, wherein the coat weight is at least 15 g/m2 and no greater than 100 g/m2.

11. The abrasive article of claim 1, further comprising a tie layer underlying the inter layer.

12. The abrasive article of claim 12, wherein the tie layer comprises an elastic modulus of at least 1×104 Pa to no greater than 5×109 Pa.

13. The abrasive article of claim 12, the tie layer comprises: an elastic modulus of: 1) less than 1×106 Pa;2) 1×104 to 1×106 Pa; or3) 6×105 to 7×105;a shaped structure height of 15-25 microns;and either: a) A coat weight of at least 25 g/m2 or at least 30 g/m2 or at least 35 g/m2 or at least 40 g/m2 or at least 50 g/m2 or at least 60 g/m2; orb) An ILTave of at least 7 microns.

15. The abrasive article of claim 12, the tie layer comprises: an elastic modulus of less than 1×106 Pa;a shaped structure height of 25-35 microns;and either: a) A coat weight of at least 25 g/m2; orb) An ILTave of at least 14 microns.

16. The abrasive article of claim 12, the tie layer comprises: an elastic modulus of at least 1×108 Pa;a shaped structure height of 15-25 microns;and either: a) A coat weight of at least 17 g/m2 and not greater than 75 g/m2; orb) An ILTave of at least 6 microns and not greater than 17 microns.

17. The abrasive article of claim 12, the tie layer comprises: an elastic modulus of at least 1×108 Pa;a shaped structure height of 25-35 microns;and either: a) A coat weight of at least 17 g/m2 and not greater than 75 g/m2; orb) An ILTave of at least 5 microns and not greater than 11 microns.

14. The abrasive article of claim 12, the tie layer comprises: an elastic modulus of at least 1×108 Pa;a shaped structure height of 25-35 microns;and either: a) A coat weight of at least 60 g/m2; orb) An ILTave of at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns.

15. A method of making an abrasive article comprising: providing a backing;depositing an interlayer and abrasive layer overlying the backing, the abrasive layer comprising a plurality of shaped structures comprising abrasive particles and a binder,an interlayer between the backing and the abrasive layer, the interlayer comprising at least one of the following: an ILTave of at least 4 microns,an ILTmax of at least 5 microns, oran ILTmin of at least 3 microns.

16. A method of using the abrasive article of claim 1 to polish a workpiece, wherein the workpiece comprises an automotive clear coat, acrylic, paint, isocyanate, urethanes, polymeric layers, coatings.