Super Smooth Paper Backing for Fine Grit Abrasives and Methods of Their Application and Use

Abstract

Methods for forming an abrasive backing having a super smooth surface are provided. The method can include applying a bond coating onto a first surface of a saturated, calendered paper; applying a barrier coating onto the bond coating to form an abrasive backing; and calendering the abrasive backing in a heated soft nip calender to produce the super smooth surface on the barrier coating. Abrasive backing sheets and abrasive sheet materials are also generally provided.

What is claimed: 
     
         1 . A method of forming an abrasive backing having a super smooth surface, the method comprising:
 applying a bond coating onto a first surface of a saturated, calendered paper;   applying a barrier coating onto the bond coating to form an abrasive backing; and   calendering the abrasive backing in a heated soft nip calender to produce the super smooth surface on the barrier coating.   
     
     
         2 . The method of  claim 1 , further comprising, prior to applying the bond coating:
 saturating a paper sheet with a saturant composition to form a saturated paper wherein the saturant composition comprises a latex polymeric binder and a film forming resin; and   calendering the saturated paper to form the saturated, calendered paper.   
     
     
         3 . The method of  claim 2 , wherein the latex polymeric binder comprises a carboxylated styrene-butadiene latex. 
     
     
         4 . The method of  claim 3 , wherein the carboxylated styrene-butadiene latex has a glass transition temperature of about −5° C. to about 5° C. 
     
     
         5 . The method of  claim 2 , wherein the film forming resin comprises a styrene maleic anhydride copolymer. 
     
     
         6 . The method of  claim 5 , wherein the styrene maleic anhydride copolymer is an esterfied styrene maleic anhydride copolymer. 
     
     
         7 . The method of  claim 1 , wherein the bond coating comprises a latex polymeric binder. 
     
     
         8 . The method of  claim 7 , wherein the latex polymeric binder of the bond coating comprises a carboxylated styrene-butadiene latex. 
     
     
         9 . The method of  claim 7 , wherein the carboxylated styrene-butadiene latex has a glass transition temperature of about −5° C. to about 5° C. 
     
     
         10 . The method of  claim 7 , wherein the bond coating further comprises a plurality of particles. 
     
     
         11 . The method of  claim 10 , wherein the particular comprises a pigment. 
     
     
         12 . The method of  claim 1 , wherein the barrier coating comprises an acrylic latex binder. 
     
     
         13 . A backing sheet, comprising:
 a saturated paper defining a first surface and a second surface, wherein the saturated paper is saturated with a saturant composition comprising a first polymeric binder and a film forming resin;   a bond coating on the first surface of the saturated paper, wherein the bond coating comprises a second polymeric binder and a plurality of particles; and   a barrier coating on the bond coating, wherein the barrier coating comprises a third polymeric binder, wherein the barrier coating defines a surface having a Bekk smoothness of about 1000 sec to about 8000 sec.   
     
     
         14 . The backing sheet of  claim 13 , wherein the first polymeric binder comprises a carboxylated styrene-butadiene latex. 
     
     
         15 . The backing sheet of  claim 14 , wherein the second polymeric binder comprises a carboxylated styrene-butadiene latex. 
     
     
         16 . The backing sheet of  claim 15 , wherein the third polymeric binder comprises an acrylic binder. 
     
     
         17 . The backing sheet of  claim 16 , wherein the plurality of particles comprises a pigment. 
     
     
         18 . An abrasive sheet material, comprising:
 a saturated paper defining a first surface and a second surface, wherein the saturant composition comprises a first polymeric binder and a film forming resin;   a bond coating on the first surface of the saturated paper, wherein the bond coating comprises a second polymeric binder and a plurality of particles;   a barrier coating on the bond coating, wherein the barrier coating comprises a third polymeric binder, wherein the barrier coating defines a surface having a Bekk smoothness of about 1000 sec to about 8000 sec; and   an abrasive layer on the barrier coating.