Coated abrasive articles and method of making the same

Abstract

A method of making a coated abrasive article includes: depositing precisely-shaped abrasive platelets into precisely-shaped cavities in a production tool; depositing diluent abrasive particles onto the production tool; contacting the precisely-shaped abrasive platelets and the diluent abrasive particles with a curable make layer precursor disposed on a major surface of a backing; separating the tool from the precisely-shaped abrasive platelets and the diluent abrasive particles; and at least partially curing the curable make layer precursor to provide an at least partially cured make layer precursor. Coated abrasive articles preparable by the method are also disclosed.

What is claimed is: 
     
         1 . A method of making a coated abrasive article, the method comprising sequential steps:
 a) providing a production tool comprising a carrier member having a dispensing surface having precisely-shaped cavities therein;   b) depositing precisely-shaped abrasive platelets into at least some of the precisely-shaped cavities;   c) depositing diluent abrasive particles on the dispensing surface;   d) contacting the precisely-shaped abrasive platelets and the diluent abrasive particles with a curable make layer precursor disposed on a major surface of a backing;   e) optionally separating the tool from the precisely-shaped abrasive platelets and the diluent abrasive particles; and   f) at least partially curing the curable make layer precursor to provide and at least partially cured make layer precursor.   
     
     
         2 . The method of  claim 1 , wherein the sequential steps further comprise:
 g) disposing a curable size layer precursor onto the at least partially cured make layer precursor, the precisely-shaped abrasive platelets, and the diluent abrasive particles; and   h) at least partially curing the curable size layer precursor.   
     
     
         3 . The method of  claim 1 , wherein the steps a) to e) are consecutive. 
     
     
         4 . The method of  claim 1 , wherein after step b), and before step c), at least a majority of precisely-shaped abrasive platelets are oriented with respective dihedral angles of less than or equal to 60 degrees relative to the dispensing surface of the tool. 
     
     
         5 . The method of  claim 1 , wherein after step c), at least a majority of the precisely-shaped abrasive platelets overhang a respective plurality of the diluent abrasive particles. 
     
     
         6 . The method of  claim 1 , wherein the diluent abrasive particles comprise crushed abrasive particles. 
     
     
         7 . The method of  claim 1 , wherein after step c), the precisely-shaped abrasive platelets and the diluent abrasive particles form a closed abrasive coat. 
     
     
         8 . The method of  claim 1 , wherein after step c), the precisely-shaped abrasive platelets and the diluent abrasive particles form an open abrasive coat. 
     
     
         9 . The coated abrasive article made by the method of  claim 1 . 
     
     
         10 . A coated abrasive article comprising:
 a backing having a first major surface;   a make layer disposed on and secured to the backing;   an abrasive layer contacting and secured to the make layer, wherein the abrasive layer comprises precisely-shaped abrasive platelets and diluent abrasive particles, wherein the precisely-shaped abrasive platelets comprise a second major surface disposed at a dihedral angle of less than or equal to 60 degrees relative to the first major surface of the backing, and wherein at least a majority of the precisely-shaped abrasive platelets each overhangs a respective plurality of the diluent abrasive particles; and   a size layer disposed over the make layer and the abrasive layer.   
     
     
         11 . The coated abrasive article of  claim 10 , wherein the precisely-shaped abrasive platelets are commonly aligned with respect to a longitudinal axis of the coated abrasive article. 
     
     
         12 . The coated abrasive article of  claim 10 , wherein the precisely-shaped abrasive platelets are commonly aligned with respect to a rotational axis of the coated abrasive article. 
     
     
         13 . The coated abrasive article of  claim 10 , wherein the precisely-shaped abrasive platelets comprise triangular platelets. 
     
     
         14 . The coated abrasive article of  claim 10 , wherein after step c), the precisely-shaped abrasive platelets comprise rectangular platelets. 
     
     
         15 . The coated abrasive article of  claim 10 , wherein the diluent abrasive particles comprise crushed abrasive particles. 
     
     
         16 . The coated abrasive article of  claim 10 , wherein the precisely-shaped abrasive platelets and the diluent abrasive particles form a closed abrasive coat. 
     
     
         17 . The coated abrasive article of  claim 10 , wherein the precisely-shaped abrasive platelets and the diluent abrasive particles form an open abrasive coat. 
     
     
         18 . The coated abrasive article of  claim 10 , wherein the precisely-shaped abrasive platelets are positioned substantially according to a predetermined pattern. 
     
     
         19 . A coated abrasive article comprising:
 a backing having a major surface;   a make layer disposed on and secured to the backing;   an abrasive layer contacting and secured to the make layer, wherein the abrasive layer comprises islands, each island comprising at least one precisely-shaped abrasive platelet and diluent abrasive particles, and wherein the islands are isolated one from another; and   a size layer disposed over the make layer and the abrasive layer.   
     
     
         20 . The coated abrasive article of  claim 19 , wherein the diluent abrasive particles are predominantly disposed beneath respective overhangs of at least a majority of the precisely-shaped abrasive platelets. 
     
     
         21 . The coated abrasive article of  claim 19 , wherein the islands are separated from each other by at least twice the minimum distance between closest precisely-shaped abrasive platelets of adjacent islands. 
     
     
         22 . The coated abrasive article of  claim 19 , wherein the precisely-shaped abrasive platelets are positioned substantially according to a predetermined pattern. 
     
     
         23 . The coated abrasive article of  claim 19 , wherein the precisely-shaped abrasive platelets are commonly aligned with respect to a longitudinal axis of the coated abrasive article. 
     
     
         24 . The coated abrasive article of  claim 19 , wherein the precisely-shaped abrasive platelets are commonly aligned with respect to a rotational axis of the coated abrasive article.