Abrasive articles and methods of making and using the same

Abstract

A coated abrasive article having a reinforced vulcanized fiber backing with an abrasive layer affixed thereto and methods of making and using the same. The reinforced vulcanized fiber backing has a backsize that comprises a reaction product of components selected from the group consisting of curable latex emulsions, phenolic resins, and combinations thereof.

1 . A coated abrasive article comprising a vulcanized fiber backing having first and second opposed major surfaces, an abrasive layer affixed to the first major surface, and a backsize affixed to the second major surface, wherein the backsize has a dry basis weight of from 8 to 90 grams per square meter of the coated abrasive article, and wherein the backsize comprises a reaction product of components selected from the group consisting of curable latex emulsions, phenolic resins, and combinations thereof.  
   
   
       2 . A coated abrasive article according to  claim 1 , wherein a presize is affixed to the first major surface of the vulcanized fiber backing.  
   
   
       3 . A coated abrasive article according to  claim 2 , wherein the presize comprises the same components as the backsize.  
   
   
       4 . A coated abrasive article according to  claim 1 , wherein the abrasive article comprises an abrasive disc or an endless belt.  
   
   
       5 . A coated abrasive article according to  claim 1 , wherein the backsize comprises a curable latex emulsion and has a dry basis weight of from 8 to 25 grams per square meter of the coated abrasive article.  
   
   
       6 . A coated abrasive article according to  claim 1 , wherein the backsize comprises a phenolic resin and has a dry basis weight of from 15 to 90 grams per square meter of the coated abrasive article.  
   
   
       7 . A coated abrasive article according to  claim 1 , wherein the vulcanized fiber backing has a thickness in a range of from 0.5 to 1.3 millimeters.  
   
   
       8 . A coated abrasive article according to  claim 1 , wherein the abrasive layer comprises make and size layers.  
   
   
       9 . A coated abrasive article according to  claim 1 , wherein the abrasive layer comprises a dispersion of abrasive particles in a binder.  
   
   
       10 . A coated abrasive article according to  claim 1 , wherein the abrasive layer comprises a reaction product of components comprising at least one of a polyepoxide, a poly(meth)acrylate, urea-formaldehyde resin, melamine-formaldehyde resin, phenolic resin, or a combination thereof.  
   
   
       11 . A coated abrasive article according to  claim 1 , wherein the abrasive article further comprises at least one of a presize, subsize, saturant, tie layer or supersize.  
   
   
       12 . A coated abrasive article according to  claim 1 , wherein the abrasive article comprises a disc, and wherein the abrasive article further comprises a mechanical fastener welded to the backsize.  
   
   
       13 . A method of abrading a surface of a workpiece, the method comprising: 
 providing a coated abrasive article according to  claim 1 ,    frictionally contacting the abrasive layer with a surface of the workpiece; and    moving at least one of the abrasive layer and the surface of the workpiece relative to the other to abrade at least a portion of the surface of the workpiece.    
   
   
       14 . A method of making a coated abrasive article, the method comprising: 
 providing a vulcanized fiber backing having first and second opposed major surfaces;    coating a curable backsize precursor onto the second major surface of the vulcanized fiber backing, and curing the backsize precursor to provide a backsize, wherein the backsize has a dry basis weight of from 8 to 90 grams per square meter of the coated abrasive article, and wherein the backsize precursor comprises at least one material selected from the group consisting of curable latex emulsions, phenolic resins, and combinations thereof; and    affixing an abrasive layer to the first major surface of the vulcanized fiber backing.    
   
   
       15 . A method of making a coated abrasive article according to  claim 14 , further comprising converting the coated abrasive article into an abrasive disc or an endless belt.  
   
   
       16 . A method of making a coated abrasive article according to  claim 14 , wherein the backsize comprises a curable latex emulsion and has a dry basis weight of from 8 to 25 grams per square meter of the coated abrasive article  
   
   
       17 . A method of making a coated abrasive article according to  claim 14 , wherein the backsize comprises a phenolic resin and has a dry basis weight of from 15 to 90 grams per square meter of the coated abrasive article.  
   
   
       18 . A method of making a coated abrasive article according to  claim 14 , wherein the vulcanized fiber backing has a thickness in a range of from 0.5 to 1.3 millimeters.  
   
   
       19 . A method of making a coated abrasive article according to  claim 14 , wherein the abrasive layer comprises make and size layers.  
   
   
       20 . A method of making a coated abrasive article according to  claim 19 , further comprising applying a supersize to the size layer.  
   
   
       21 . A method of making a coated abrasive article according to  claim 14 , wherein the abrasive layer comprises abrasive particles distributed in a binder.  
   
   
       22 . A method of making a coated abrasive article according to  claim 14 , wherein the abrasive layer comprises a reaction product of components comprising at least one of a polyepoxide, a poly(meth)acrylate, urea-formaldehyde resin, melamine-formaldehyde resin, phenolic resin, or a combination thereof.  
   
   
       23 . A method of making a coated abrasive article according to  claim 14 , further comprising welding a mechanical fastener to the backsize.