Abrasive article and method of making the same

Abstract

An abrasive article comprises abrasive particles adhered to a substrate by a binder material. The binder material comprises an at least partially cured resole phenolic resin and an organic polymeric rheology modifier. The amount of the at least partially cured resole phenolic resin comprises from 75 to 99.99 weight percent of the combined weight of the at least partially cured resole phenolic resin and the organic polymeric rheology modifier. Methods of making the abrasive article are also disclosed.

1 . A method of making an abrasive article comprising:
 disposing a curable composition on a substrate, wherein the curable composition comprises a resole phenolic resin and an organic polymeric rheology modifier selected from hydrophobically-modified ethoxylated urethane polymers, wherein the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer, and, on a solids basis, wherein the amount of the resole phenolic resin comprises from 75 to 99.99 weight percent of the combined weight of the resole phenolic resin and the organic polymeric rheology modifier;   adhering abrasive particles to the curable composition; and   at least partially curing the curable composition.   
     
     
         2 . (canceled) 
     
     
         3 . The method of  claim 1 , wherein, on a solids basis, the amount of the resole phenolic resin comprises from 85 to 99.99 weight percent of the combined weight of the resole phenolic resin and the organic polymeric rheology modifier. 
     
     
         4 . The method of  claim 1 , wherein the abrasive particles comprise shaped abrasive particles. 
     
     
         5 . The method of  claim 4 , wherein the shaped abrasive particles comprise precisely-shaped abrasive particles. 
     
     
         6 . The method of  claim 4 , wherein the shaped abrasive particles comprise precisely-shaped triangular platelets. 
     
     
         7 . The method of  claim 1 , wherein the substrate comprises a backing member having first and second opposed major surfaces, the method further comprising:
 disposing a size layer precursor onto at least a portion of the abrasive particles and said at least partially cured curable composition; and   at least partially curing the size layer precursor to provide a coated abrasive article.   
     
     
         8 . The method of  claim 1 , wherein the substrate comprises a lofty open nonwoven fiber web. 
     
     
         9 . The method of  claim 1 , wherein the substrate comprises a fiber scrim. 
     
     
         10 . An abrasive article comprising abrasive particles adhered to a substrate by a binder material comprising an at least partially cured resole phenolic resin and an organic polymeric rheology modifier selected from hydrophobically-modified ethoxylated urethane polymers, wherein the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer, wherein the amount of the at least partially cured resole phenolic resin comprises from 75 to 99.99 weight percent of the combined weight of the at least partially cured resole phenolic resin and the organic polymeric rheology modifier. 
     
     
         11 . (canceled) 
     
     
         12 . The abrasive article of  claim 10 , wherein the amount of the at least partially cured resole phenolic resin comprises from 85 to 99.99 weight percent of the combined weight of the at least partially cured resole phenolic resin and the organic polymeric rheology modifier. 
     
     
         13 . The abrasive article of  claim 10 , wherein the abrasive particles comprise shaped abrasive particles. 
     
     
         14 . The abrasive article of  claim 13 , wherein the shaped abrasive particles comprise precisely-shaped abrasive particles. 
     
     
         15 . The abrasive article of  claim 13 , wherein the shaped abrasive particles comprise precisely-shaped triangular platelets. 
     
     
         16 . The abrasive article of  claim 10 , wherein the abrasive article is a coated abrasive article. 
     
     
         17 . The abrasive article of  claim 10 , wherein the abrasive article is a nonwoven abrasive article. 
     
     
         18 . The abrasive article of  claim 10 , wherein the substrate comprises a fiber scrim.