Backing and abrasive product made with the backing and method of making and using the backing and abrasive product

Abstract

The invention provides a backing for an abrasive article comprising a sheet-like polymeric substrate having a first major surface including a pattern of non-abrasive raised areas and depressed areas and an opposite second major surface including a plurality of shaped engaging elements that are one part of a two-part mechanical engagement system. An abrasive product is provided by coating at least the raised areas of the backing with an abrasive coating.

1 - 16 . (canceled)  
     
     
         17 . A method of making a backing for an abrasive article, said method comprising: 
 a) extruding molten polymeric material to form a sheet having a first major surface and an opposite second major surface;    b) contacting said first major surface of the molten sheet with a first tool having a contact surface including a pattern of non-abrasive raised areas and depressed areas to create in said first major surface a corresponding pattern of depressed areas and raised areas;    c) contacting said second major surface of the molten sheet material with a second tool having a contact surface capable of creating therein a plurality of elements selected from the group consisting of shaped engaging elements and precursors to shaped engaging elements that will be one part of a two-part mechanical engagement system; and    d) solidifying said molten sheet to provide said backing.    
     
     
         18 . The method of  claim 17  wherein steps (b) and (c) are carried out simultaneously.  
     
     
         19 . The method of  claim 17  wherein said polymer sheet is a coextruded polymer sheet comprised of at least two different polymer materials, each comprising a layer in the polymer sheet.  
     
     
         20 . The method of  claim 17  wherein said second tool includes a contact surface capable of producing erect stems each including a distal end and a contact end on said second major surface and including the further step of flattening the distal ends.  
     
     
         21 . The method of  claim 17  wherein said second tool includes a contact surface having cavities capable of producing hook elements each having a contact end on said second major surface.  
     
     
         22 . A method of making an abrasive article, said method comprising: 
 a) extruding molten polymeric material to form a sheet having a first major surface and an opposite second major surface;    b) contacting said first major surface of the molten sheet with a first tool having a contact surface including a pattern of non-abrasive raised areas and depressed areas to create in said first major surface a corresponding pattern of depressed areas and raised areas;    c) contacting said second major surface of the molten sheet material with a second tool having a contact surface capable of creating therein a plurality of elements selected from the group consisting of shaped engaging elements and precursors to shaped engaging elements that will be one part of a two-part mechanical engagement system;    d) solidifying said molten sheet to provide said backing; and    e) providing an abrasive coating at least over said raised areas of said first major surface.    
     
     
         23 . The method of  claim 22  wherein said abrasive coating is provided by: 
 a) coating at least the raised areas of said first major surface with a make coating of curable binder composition;    b) depositing abrasive particles onto the make coating of the curable composition; and    c) at least partially curing the make coating composition.    
     
     
         24 . The method of  claim 23  further including coating the make coating and abrasive particles with a size coating of a curable binder composition and curing the size coating composition.  
     
     
         25 . The method of  claim 22  wherein said abrasive particles are provided to said first surface by mixing abrasive particles with a curable binder composition to provide a mixture which cures to provide an abrasive coating, coating at least the raised areas of said first major surface with the mixture and curing the curable binder composition.  
     
     
         26 . The method of  claim 25  wherein, after coating but prior to curing the curable binder composition containing abrasive particles, contacting the coating with a surface of a tool which includes raised areas and depressed areas to provide a shaped surface to the abrasive coating.  
     
     
         27 . A backing for an abrasive article comprising a sheet-like substrate having a first major surface including a pattern of non-abrasive raised areas and depressed areas and an opposite second major surface unitarily including a plurality of shaped engaging elements that are one part of a two-part mechanical engagement system.  
     
     
         28 . The backing of  claim 27  wherein said non-abrasive raised areas are laminated to said first major surface and said depressed areas are defined by said first major surface.  
     
     
         29 . An abrasive article comprising the backing of  claim 27  having an abrasive coating coated over at least said raised areas.  
     
     
         30 . A method of making a shaped backing for a coated abrasive article, said method comprising: 
 a) providing a sheet-like backing having a first major surface and an opposite second major surface which unitarily includes one part of a two-part mechanical attachment system; and    b) applying a plurality of separated, shaped structures to said first major surface, each of said structures having an attachment end attached to said first major surface and a distal end spaced from said first major surface with said shaped structures comprising distal ends aligned generally in the same plane.    
     
     
         31 . The method of  claim 30  wherein said plurality of separated, shaped structures are applied by applying molded molten polymer structures to said first major surface and permitting the molded molten polymer structures to cool to provide said separated, shaped structures.  
     
     
         32 . The method of  claim 31  wherein said backing is a fabric backing.