Lay flat coated abrasive discs

Abstract

The present invention relates generally to coated abrasive articles that lay flat, in particular coated abrasive discs, as well as methods of making and using said coated abrasive articles.

What is claimed is: 
     
         1 . A coated abrasive article comprising:
 an abrasive layer disposed on a backing material, wherein the backing material comprises:
 a backing substrate having a first side and a second side; and 
 a layer of polymeric polyethylene composition disposed on the first side of the backing substrate;
 wherein the abrasive layer is disposed directly in contact with the polymeric polyethylene composition. 
 
   
     
     
         2 . The coated abrasive article of  claim 1 , wherein the coated abrasive article lays flat. 
     
     
         3 . The coated abrasive article of  claim 1 , wherein the coated abrasive article has a curvature of not greater than 10% of the diameter of the abrasive article. 
     
     
         4 . The coated abrasive article of  claim 1 , wherein the abrasive layer comprises a make coat or a size coat having a Young's modulus (stiffness) of at least 150 kpsi, such as at least 200 kpsi, at least 250 kpsi, at least 300 kpsi, at least 350 kpsi, at least 400 kpsi, at least 450 kpsi, or at least 500 kpsi. 
     
     
         5 . The coated abrasive article of  claim 4 , wherein the abrasive layer comprises a make coat or a size coat having a Young's modulus (stiffness) of not greater than 900 kpsi, such as not greater than 850 kpsi, not greater than 800 kpsi, not greater than 750 kpsi, not greater than 700 kpsi, not greater than 650 kpsi, or not greater than 600 kpsi. 
     
     
         6 . The coated abrasive article of  claim 1 , wherein the polymeric polyethylene composition comprises low density polyethylene, high density polyethylene, or a combination thereof. 
     
     
         7 . The coated abrasive article of  claim 1 , wherein the layer of polymeric polyethylene composition comprises a thickness of at least 0.25 mil to not greater than 0.5 mil, such as at least 1 mil to not greater than 3 mil, or at least 1.5 mil to not greater than 2.5 mil. 
     
     
         8 . The coated abrasive article of  claim 1 , further comprising a layer of polymeric acrylate composition disposed on a second side of the backing substrate. 
     
     
         9 . The coated abrasive article of  claim 8 , wherein the polymeric acrylate composition comprises ethyl acrylate, ethylene acrylate, ethylene-methyl acrylate, ethylene-ethyl acrylate, or a combination thereof. 
     
     
         10 . The coated abrasive article of  claim 8 , wherein the layer of polymeric acrylate composition comprises a thickness of at least 0.1 mil to not greater than 3 mil, such as at least 0.25 mil to not greater than 2.5 mil, or at least 0.5 mil to not greater than 2 mil. 
     
     
         11 . The coated abrasive article of  claim 1 , wherein the backing substrate comprises a polymeric film formed from at least one of polyester and polyethylene terephthalate. 
     
     
         12 . The coated abrasive article of  claim 11 , wherein the polymeric film comprises a thickness of at least 1 mil to not greater than 10 mil, such as at least 2 mil to not greater than 8 mil, at least 3 mil to not greater than 7 mil, or at least 4 mil to not greater than 6 mil. 
     
     
         13 . The coated abrasive article of  claim 11 , wherein the polymeric film comprises a surface energy of at least 40 dyne/cm 2 , such as at least 45 dyne/cm 2 . 
     
     
         14 . The coated abrasive article of  claim 13 , wherein the polymeric film is corona treated. 
     
     
         15 . The coated abrasive article of  claim 1 , wherein the abrasive layer comprises a polymeric make coat composition and abrasive particles disposed in the make coat composition. 
     
     
         16 . The coated abrasive article of  claim 15 , wherein the make coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof. 
     
     
         17 . The coated abrasive article of  claim 15 , wherein the abrasive layer further comprises a polymeric size coat composition disposed on the make coat composition and abrasive particles. 
     
     
         18 . The coated abrasive article of  claim 15 , wherein the size coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof. 
     
     
         19 . The coated abrasive article of  claim 15 , wherein the abrasive particles comprise diamond, cubic boron nitride, or a combination thereof. 
     
     
         20 . The coated abrasive article of  claim 19 , wherein the abrasive particles comprise a grit size of 5 microns to 500 microns.