Coated abrasive article and method of making the same

Abstract

A coated abrasive article comprises a backing having first and second opposed major surfaces, a make layer disposed on at least a portion of the first major surface and bonding abrasive particles to the backing, a size layer overlaid on at least a portion of the make layer and the abrasive particles, and an optional supersize layer. At least one of the size layer or the optional supersize layer comprises an at least partially cured resole phenolic resin and an organic polymeric rheology modifier, and 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. A method of making the coated abrasive article is also disclosed.

1 . A method of making a coated abrasive article comprising:
 providing a backing having first and second opposed major surfaces, wherein a make layer is disposed on at least a portion of the first major surface and bonds abrasive particles to the backing;   coating a size layer precursor over at least a portion of the make layer and the abrasive particles, wherein the size layer precursor comprises a resole phenolic resin and an organic polymeric rheology modifier, wherein the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer, and, on a solids basis, and 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; and   at least partially curing the size layer precursor to provide a size layer;   wherein the size layer precursor comprises a resole phenolic resin and an organic polymeric rheology modifier, wherein the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer, and, on a solids basis, and 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.   
     
     
         2 . The method of  claim 1 , wherein at least one of said at least partially curing the size layer precursor or said at least partially curing the supersize layer precursor occurs in a festoon oven. 
     
     
         3 . The method of  claim 1 , wherein at least one of the size layer precursor or the optional supersize layer precursor has a basis weight of 5 to 1100 grams per square meter. 
     
     
         4 . (canceled) 
     
     
         5 . 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. 
     
     
         6 . The method of  claim 1 , wherein the abrasive particles comprise shaped abrasive particles. 
     
     
         7 . The method of  claim 6 , wherein the shaped abrasive particles comprise precisely-shaped abrasive particles. 
     
     
         8 . The method of  claim 6 , wherein the shaped abrasive particles comprise precisely-shaped three-sided platelets. 
     
     
         9 . A coated abrasive article comprising:
 a backing having first and second opposed major surfaces,   a make layer disposed on at least a portion of the first major surface and bonding abrasive particles to the backing;   a size layer overlaid on at least a portion of the make layer and the abrasive particles; and   an optional supersize layer,   wherein at least one of the size layer or the optional supersize layer comprises an at least partially cured resole phenolic resin and an organic polymeric rheology modifier, wherein the organic polymeric rheology modifier comprises an alkali-swellable/soluble polymer, and 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.   
     
     
         10 . (canceled) 
     
     
         11 . The coated abrasive article of  claim 9 , 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. 
     
     
         12 . The coated abrasive article of  claim 9 , wherein the abrasive particles comprise shaped abrasive particles. 
     
     
         13 . The coated abrasive article of  claim 12 , wherein the shaped abrasive particles comprise precisely-shaped abrasive particles. 
     
     
         14 . The coated abrasive article of  claim 12 , wherein the shaped abrasive particles comprise precisely-shaped three-sided platelets.