Abrasive article with calendered combination

Abstract

Aspects of the present disclosure relate to a method of making an abrasive article. The method can include providing a combination of a mesh backing and a fastener. The mesh backing has a first side and a second side and the mesh backing has a fastener disposed on the second side and intertwined through the mesh backing therein. The combination comprises a raised portion on the first side having a first dimension. The method can include calendering the first side of the mesh backing to form a calendered mesh backing such that the raised portion results in a second dimension. The second dimension is less than the first dimension. The method can include depositing a curable make layer precursor on a major surface of the calendered mesh backing, deposing a plurality of abrasive particles onto the curable make layer precursor, and at least partially curing the curable make layer precursor.

1 . A method of making an abrasive article, comprising:
 providing a combination of a mesh backing and a fastener, wherein the mesh backing has a first side and a second side, the mesh backing has a fastener disposed on the second side and intertwined through the mesh backing therein, wherein the combination comprises a raised portion on the first side having a first dimension,   calendering the first side of the mesh backing to form a calendered mesh backing such that the raised portion of the calendered mesh backing results in a second dimension, the second dimension is less than the first dimension;   depositing a curable make layer precursor on a major surface of the calendered mesh backing;   depositing a plurality of abrasive particles onto the curable make layer precursor; and   at least partially curing the curable make layer precursor.   
     
     
         2 . The method of  claim 1 , wherein the mesh backing is a woven fabric, a plane of the mesh backing is formed by weft yarns of the woven fabric, the raised portion is defined by raised picks from warp yarns. 
     
     
         3 . The method of  claim 1 , wherein the raised portion is raised relative to a plane of the mesh backing. 
     
     
         4 . The method of  claim 1 , wherein the mesh backing is formed from a yarn having a yarn thickness, a first dimension of the raised portion is at least two times a diameter of the yarn thickness when stretched. 
     
     
         5 . The method of  claim 1 , wherein the mesh backing is a knitted fabric. 
     
     
         6 . The method of  claim 5 , wherein the knitted fabric is a warp knitted fabric. 
     
     
         7 . (canceled) 
     
     
         8 . The method of  claim 5 , wherein the knitted fabric comprises a plurality of loops, a loop comprises a head, two legs, and two feet, wherein a foot meshes through a head of another loop. 
     
     
         9 . The method of  claim 8 , wherein the raised portion is formed by a stich involving at least two feet from a first loop, and a head of a second loop. 
     
     
         10 . The method of  claim 9 , wherein the raised portion is formed from a stich of at least two yarn segments. 
     
     
         11 . The method of  claim 10 , wherein the raised portion is formed from a bobble. 
     
     
         12 . The method of  claim 5 , the knitted fabric comprising a first yarn and a second yarn, the second yarn is intermeshed with the first yarn on the second side to form part of a fastener. 
     
     
         13 . The method of  claim 1 , wherein the second dimension decreases at least 65% from the first dimension in response to the calendering using the Raised Portion Topographical Profile Method. 
     
     
         14 . The method of  claim 1 , wherein the calendering does not occur after the make coat or the abrasive particles are deposited. 
     
     
         15 . The method of  claim 1 , wherein the mesh backing is an extruded polymer mesh and the raised portion is formed by intermeshed loops of the fastener. 
     
     
         16 . The method of  claim 1 , wherein the calendering results in at least a 20 percent decrease of open area of the mesh backing relative to an uncalendered mesh backing. 
     
     
         17 . The method of  claim 1 , wherein a max KP in a machine direction of the calendered mesh backing can be at least a 25% decrease relative to a max KP in a machine direction of a comparable uncalendered mesh backing. 
     
     
         18 . An abrasive article formed according to the method of  claim 1 . 
     
     
         19 . A system, comprising:
 a calendering system configured to receive the combination of  claim 1 , the calendering system comprising:
 a tensioner, 
 an upper roll, and 
 a lower roll, wherein the upper roll and the lower roll are configured to apply a pressure and a temperature to the combination, a first temperature of the upper roll and a second temperature of the lower roll are different; and 
 a coating system configured to coat a make layer, abrasive particles, and a size layer onto a calendered combination. 
   
     
     
         20 . The system of  claim 19 , wherein a difference between the first temperature and the second temperature is no greater than 400 degrees fahrenheit. 
     
     
         21 . The system of  claim 19 , wherein the applied pressure of the upper roll and the lower roll is at least 300 pounds per linear inch, and the temperature is at least 250 degrees fahrenheit in at least one of the upper roll or the lower roll.