Embossed structured abrasive article and method of making and using the same

Abstract

An embossed structured abrasive article having an inelastic dense thermoplastic film backing and a structured abrasive layer. Both the backing and the structured abrasive layer have superposed embossed features. Methods of making and using embossed structured abrasive articles are also disclosed.

1 . An embossed structured abrasive article consisting of: 
 a backing having first and second major surfaces and comprising an inelastic dense thermoplastic film;    an optional adhesive layer in contact and coextensive with, and affixed to, the first major surface;    a structured abrasive layer in contact and coextensive with, and affixed to, either the first surface of the backing or the optional adhesive layer, wherein the structured abrasive layer consists of outwardly protruding precisely shaped abrasive composites comprising abrasive particles and a binder, and wherein both the backing and the structured abrasive layer have superposed embossed features; and    an optional attachment interface layer affixed to the second major surface; wherein the embossed structured abrasive article is free of porous resilient components.    
   
   
       2 . An embossed structured abrasive article according to  claim 1 , wherein the optional adhesive layer is present.  
   
   
       3 . An embossed structured abrasive article according to  claim 1 , wherein the optional attachment interface layer is present.  
   
   
       4 . An embossed structured abrasive article according to  claim 1 , wherein from 5 to 95 percent the structured abrasive layer is included within the embossed features of the backing, based on the total area of the backing or optional adhesive layer that contacts the structured abrasive layer.  
   
   
       5 . An embossed structured abrasive article according to  claim 1 , wherein the second major surface is planar.  
   
   
       6 . An embossed structured abrasive article according to  claim 1 , wherein the precisely shaped abrasive composites are substantially identical.  
   
   
       7 . An embossed structured abrasive article according to  claim 1 , wherein the embossed features comprise dimples.  
   
   
       8 . An embossed structured abrasive article according to  claim 1 , wherein the embossed features comprise posts.  
   
   
       9 . An embossed structured abrasive article according to  claim 1 , wherein the abrasive particles have an average size in a range of from at least 0.01 up to and including 1,500 micrometers.  
   
   
       10 . An embossed structured abrasive article according to  claim 1 , wherein the abrasive composites have an areal density in a range of from at least 150 up to and including 15,000 shaped abrasive composites per square centimeter of the structured abrasive layer.  
   
   
       11 . An embossed structured abrasive article according to  claim 1 , wherein the structured abrasive article comprises a structured abrasive disc.  
   
   
       12 . An embossed structured abrasive article according to  claim 11 , wherein the disc has a diameter in a range of from 0.6 centimeter to 15.2 centimeters.  
   
   
       13 . A method of abrading a workpiece, the method comprising: 
 a) providing an embossed structured abrasive article according to  claim 1;     b) providing a workpiece having a hardened polymeric layer thereon;    c) frictionally contacting at least a portion of the structured abrasive layer with the polymeric layer; and    d) moving at least one of the workpiece and the structured abrasive layer relative to the other to abrade at least a portion of the polymeric layer.    
   
   
       14 . A method according to  claim 13 , further comprising contacting a liquid with at least a portion of the polymeric layer and at least a portion of the structured abrasive layer during step d).  
   
   
       15 . A method according to  claim 13 , wherein the polymeric layer comprises an automotive clearcoat.  
   
   
       16 . A method of making an embossed structured abrasive article, the method comprising: 
 providing a backing having first and second major surfaces and comprising an inelastic dense thermoplastic film;    affixing an adhesive layer in contact and coextensive with the first major surface;    affixing a structured abrasive layer in contact and coextensive with the adhesive layer, wherein the structured abrasive layer consists of outwardly protruding precisely shaped abrasive composites comprising abrasive particles and a binder;    embossing the backing and structured abrasive layer to provide superposed embossed features in the backing and structured abrasive layer;    optionally affixing an attachment interface layer to the second major surface; and thereby providing an embossed structured abrasive article that is free of porous resilient components.    
   
   
       17 . A method according to  claim 16 , further comprising converting the structured abrasive article to at least one structured abrasive disc.  
   
   
       18 . A method according to  claim 16 , wherein from 5 to 95 percent the structured abrasive layer is included within the embossed features of the backing, based on the total area of the backing or optional adhesive layer that contacts the structured abrasive layer.  
   
   
       19 . A method of making an embossed structured abrasive article, the method comprising: 
 providing an inelastic dense thermoplastic film backing having first and second major surfaces;    affixing a structured abrasive layer to the backing, wherein the structured abrasive layer contacts and is coextensive with the adhesive layer, and wherein the structured abrasive layer consists of outwardly protruding precisely shaped abrasive composites comprising abrasive particles and a binder;    embossing the backing and structured abrasive layer to provide superposed embossed features in the backing and structured abrasive layer;    optionally affixing an attachment interface layer to the second major surface; and thereby providing an embossed structured abrasive article that is free of porous resilient components.    
   
   
       20 . A method according to  claim 19 , further comprising converting the structured abrasive article to at least one structured abrasive disc.  
   
   
       21 . A method according to  claim 19 , wherein from 5 to 95 percent the structured abrasive layer is included within the embossed features of the backing, based on the total area of the backing or optional adhesive layer that contacts the structured abrasive layer.