Flexible abrasive article and method of using the same

Abstract

A flexible abrasive article includes a unitary backing having first and second opposed major surfaces and comprising a polyurethane. In some embodiments, the backing has an average thickness of from 4 to 6 mils (102 to 152 microns), a tensile strength of 500 to 3200 psi (3.45 to 22.1 MPa), and an ultimate elongation of 230 to 530 percent. In some embodiments, the flexible abrasive article has a tensile strength of 400 to 2400 psi (2.8 to 16.5 MPa), and a ultimate elongation of 180 to 380 percent. An abrasive layer is disposed on and secured to the unitary backing.

1 . A flexible abrasive article comprising:
 a unitary backing having first and second opposed major surfaces and comprising a thermoplastic polyurethane, wherein the backing has an average thickness of from 4 to 6 mils, a tensile strength of 500 to 3200 psi, and a ultimate elongation of 230 to 530 percent; and   an abrasive layer disposed on and secured to the unitary backing, wherein the abrasive layer comprises:
 a make layer disposed on at least a portion of the first major surface of the unitary backing, wherein the make layer comprises a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth)acrylate; 
 abrasive particles secured to the make layer; and 
 a size layer disposed on at least a portion of the make layer and abrasive particles, wherein the size layer precursor comprises a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth)acrylate, wherein the second major surface of the unitary backing forms an outer major surface of the flexible abrasive article. 
   
     
     
         2 . The flexible abrasive article of  claim 1 , wherein the abrasive particles have a nominal size grade of less than or equal to an ANSI grade P80 or greater than or equal to an ANSI grade P320. 
     
     
         3 . The flexible abrasive article of  claim 1 , wherein the abrasive particles have a nominal size grade of less than or equal to an ANSI grade P180 or greater than or equal to ANSI grade P320. 
     
     
         4 . The flexible abrasive article of  claim 1 , wherein the average thickness of the backing is from 4.5 to 5.5 mils. 
     
     
         5 . The flexible abrasive article of  claim 1 , wherein the backing comprises a thermoplastic polyurethane. 
     
     
         6 . The flexible abrasive article  claim 1 , wherein the flexible abrasive article is translucent. 
     
     
         7 . The flexible abrasive article of  claim 1 , further comprising a supersize layer disposed on at least a portion of the size layer. 
     
     
         8 . The flexible abrasive article of  claim 1 , wherein the backing has a maximum tensile strength of 1000 to 2500 psi and a maximum ultimate elongation of 300 to 460 percent. 
     
     
         9 . The flexible abrasive article of  claim 1 , wherein the backing has a maximum tensile strength of 1600 to 2100 psi and a maximum ultimate elongation of 350 to 410 percent. 
     
     
         10 . A flexible abrasive article comprising:
 a unitary backing having first and second opposed major surfaces and comprising a thermoplastic polyurethane, wherein the unitary backing has an average thickness of from 4 to 6 mils; and   an abrasive layer disposed on and secured to the unitary backing, wherein the abrasive layer comprises:
 a make layer disposed on at least a portion of the first major surface of the unitary backing, wherein the make layer comprises a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth)acrylate; 
 abrasive particles secured to the make layer; and 
 a size layer disposed on at least a portion of the make layer and abrasive particles, wherein the size layer precursor comprises a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth)acrylate, wherein the second major surface of the unitary backing forms an outer major surface of the flexible abrasive article, 
   
       wherein the flexible abrasive article has a tensile strength of 400 to 2400 psi (2.8 to 16.5 MPa), and a ultimate elongation of 180 to 380 percent. 
     
     
         11 . 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 with a surface of a workpiece; and   moving at least one of the abrasive layer or the surface of the workpiece to abrade the surface of the workpiece.   
     
     
         12 . The method of  claim 11 , wherein the workpiece comprises painted or unpainted wood or metal. 
     
     
         13 . The method of  claim 11 , wherein the workpiece comprises architectural trim having three-dimensional detail. 
     
     
         14 . The method of  claim 11 , wherein the flexible abrasive article is hand held.