Flexible abrasive article and methods of making and using the same

Abstract

Flexible abrasive article comprising a compressible backing having first and second opposed major surfaces; an elastic polyurethane film affixed to at least a portion of the first major surface of the compressible backing; an optional extensible tie layer affixed to at least a portion of the elastic polyurethane film; and an abrasive layer affixed to at least a portion of the optional extensible tie layer or elastic polyurethane film, the abrasive layer comprising abrasive particles and a binder. Methods of making and using the flexible abrasive article are also disclosed.

1 . A flexible abrasive article comprising: 
 a compressible backing having first and second opposed major surfaces;    an elastic polyurethane film affixed to at least a portion of the first major surface of the compressible backing; and    an abrasive layer affixed to at least a portion of the polyurethane film, the abrasive layer comprising abrasive particles and a binder.    
   
   
       2 . A flexible abrasive article according to  claim 1 , wherein the polyurethane film has a treated surface, and wherein the abrasive layer is affixed to at least a portion of the treated surface.  
   
   
       3 . A flexible abrasive article according to  claim 1 , further comprising an extensible tie layer affixed to at least a portion of the polyurethane film, wherein the abrasive layer is affixed to at least a portion of the extensible tie layer.  
   
   
       4 . A flexible abrasive article according to  claim 3 , wherein at least one of the polyurethane film, extensible tie layer, and abrasive layer is foraminous.  
   
   
       5 . A flexible abrasive article according to  claim 3 , wherein at least one of the polyurethane film, extensible tie layer, and abrasive layer is needletacked.  
   
   
       6 . A flexible abrasive article according to  claim 3 , wherein each of the polyurethane film, extensible tie layer, and coated abrasive layer are foraminous, and wherein there exist a plurality of pores that extend from the second major surface of the backing through the abrasive layer.  
   
   
       7 . A flexible abrasive article according to  claim 1 , wherein the abrasive layer comprises a plurality of shaped abrasive composites.  
   
   
       8 . A flexible abrasive article according to  claim 1 , wherein the compressible backing comprises an open cell foam.  
   
   
       9 . A flexible abrasive article according to  claim 1 , wherein the polyurethane film is affixed to the compressible backing by a layer of adhesive disposed therebetween.  
   
   
       10 . A flexible abrasive article according to  claim 1 , wherein the polyurethane film contacts the compressible backing.  
   
   
       11 . A flexible abrasive article according to  claim 1 , wherein the compressible backing has a bulk density of at least 0.03 grams per cubic centimeter.  
   
   
       12 . A flexible abrasive article according to  claim 1 , wherein the compressible backing has a thickness of at least 2 millimeters.  
   
   
       13 . A flexible abrasive article according to  claim 1 , wherein the polyurethane film has a thickness in a range of from 0.02 to 0.1 millimeter.  
   
   
       14 . A flexible abrasive article according to  claim 1 , further comprising an attachment system affixed to the second major surface of the compressible backing.  
   
   
       15 . A flexible abrasive article according to  claim 14 , wherein the attachment system comprises hooks or loops.  
   
   
       16 . A flexible abrasive article according to  claim 1 , wherein the abrasive article is selected from the group consisting of an abrasive disc and an abrasive pad.  
   
   
       17 . A flexible abrasive article according to  claim 1 , wherein the compressible backing comprises a multiplicity of separated resilient bodies connected to each other in a generally planar array, which provides open spaces between adjacent connected bodies, each body having a first and second opposed surfaces.  
   
   
       18 . A flexible abrasive article according to  claim 17 , further comprising an extensible tie layer affixed to at least a portion of the polyurethane film, wherein the abrasive layer is affixed to at least a portion of the extensible tie layer, wherein each the elastic polyurethane film, extensible tie layer, and abrasive layer has a plurality of openings therethrough, some of the openings substantially corresponding in position to openings in the compressible backing.  
   
   
       19 . A flexible abrasive article according to  claim 17 , wherein the binder comprises a reaction product of a polymerizable binder precursor comprising at least one of acrylic acid or methacrylic acid.  
   
   
       20 . A method of abrading a workpiece, the method comprising: 
 providing a flexible abrasive article according to  claim 1;     frictionally contacting at least a portion of the abrasive layer of the flexible abrasive article with a surface of a 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.    
   
   
       21 . A method according to  claim 20 , wherein the abrasive layer comprises shaped abrasive composites.  
   
   
       22 . A method according to  claim 20 , wherein the surface of the workpiece comprises a painted surface.  
   
   
       23 . A method according to  claim 20 , further comprising: 
 providing a lubricant to the surface of the workpiece.    
   
   
       24 . A method of making a flexible abrasive article, the method comprising: 
 affixing an elastic polyurethane film to a first major surface of a compressible backing which also has an opposite second major surface;    applying a curable composition comprising a polymerizable binder precursor and abrasive particles to the elastic polyurethane film; and    at least partially curing the curable composition to provide an abrasive layer.    
   
   
       25 . A method of making a flexible abrasive article according to  claim 24 , further comprising; 
 imparting a textured surface to the curable composition with a production tool; and    separating the production tool from the at least partially cured curable composition to produce a plurality of shaped abrasive composites.    
   
   
       26 . A method of making a flexible abrasive article according to  claim 24 , further comprising affixing an attachment system to the second major surface of the compressible backing.  
   
   
       27 . A method of making a flexible abrasive article according to  claim 24 , wherein the elastic polyurethane film is affixed to the compressible backing by a layer of adhesive disposed therebetween.  
   
   
       28 . A method of making a flexible abrasive article according to  claim 24 , wherein the elastic polyurethane film contacts the compressible backing.  
   
   
       29 . A method of making a flexible abrasive article according to  claim 24 , further comprises forming a plurality of openings through at least the elastic polyurethane film and abrasive layer, the openings substantially corresponding in position to openings in the compressible backing.  
   
   
       30 . A method of making a flexible abrasive article according to  claim 29 , wherein forming the plurality of openings comprises needletacking.  
   
   
       31 . A method of making a flexible abrasive article according to  claim 24 , wherein the compressible backing comprises open cell foam.  
   
   
       32 . A method of making a flexible abrasive article according to  claim 24 , further comprising affixing an attachment system to the second major surface of the compressible backing.  
   
   
       33 . A method of making a flexible abrasive article according to  claim 24 , wherein the compressible backing comprises a multiplicity of separated resilient bodies connected to each other in a generally planar array, which provides open spaces between adjacent connected bodies, each body having a first and second opposed surfaces.  
   
   
       34 . A method of making a flexible abrasive article according to  claim 24 , further comprises forming a plurality of openings through at least the elastic polyurethane film and abrasive layer, some of the openings substantially corresponding in position to openings in the compressible backing.  
   
   
       35 . A method of making a flexible abrasive article according to  claim 24 , wherein the polymerizable binder precursor comprises at least one of acrylic acid or methacrylic acid.  
   
   
       36 . A method of making a flexible abrasive article, the method comprising: 
 affixing an elastic polyurethane film to a first major surface of a compressible backing, which also has an opposite second major surface;    affixing an extensible tie layer to the polyurethane film;    applying a curable composition comprising a polymerizable binder precursor and abrasive particles to the extensible tie layer; and    at least partially curing the curable composition to provide an abrasive layer.    
   
   
       37 . A method of making a flexible abrasive article according to  claim 36 , further comprising; 
 imparting a textured surface to the curable composition with a production tool; and    separating the production tool from the at least partially cured curable composition to produce a plurality of shaped abrasive composites.    
   
   
       38 . A method of making a flexible abrasive article according to  claim 36 , further comprising affixing an attachment system to the second major surface of the compressible backing.  
   
   
       39 . A method of making a flexible abrasive article according to  claim 36 , wherein the elastic polyurethane film is affixed to the compressible backing by a layer of adhesive disposed therebetween.  
   
   
       40 . A method of making a flexible abrasive article according to  claim 36 , wherein the elastic polyurethane film contacts the compressible backing.  
   
   
       41 . A method of making a flexible abrasive article according to  claim 36 , further comprising forming a plurality of openings through at least the elastic polyurethane film, extensible tie layer, and abrasive layer, at least some of the openings substantially corresponding in position to openings in the compressible backing.  
   
   
       42 . A method of making a flexible abrasive article according to  claim 41 , wherein forming the plurality of openings comprises needletacking.  
   
   
       43 . A method of making a flexible abrasive article according to  claim 36 , wherein the compressible backing comprises open cell foam.  
   
   
       44 . A method of making a flexible abrasive article according to  claim 36 , further comprising affixing an attachment system to the second major surface of the compressible backing.  
   
   
       45 . A method of making a flexible abrasive article according to  claim 36 , wherein the compressible backing comprises a multiplicity of separated resilient bodies connected to each other in a generally planar array in a pattern, which provides open spaces between adjacent connected bodies, each body having a first and second opposed surfaces.  
   
   
       46 . A method of making a flexible abrasive article according to  claim 36 , further comprises forming a plurality of openings through at least the elastic polyurethane film, extensible tie layer and abrasive layer, the openings substantially corresponding in position to openings in the compressible backing.  
   
   
       47 . A method of making a flexible abrasive article according to  claim 36 , wherein the polymerizable binder precursor comprises at least one of acrylic acid or methacrylic acid.