Structured abrasive article with interlayer

Abstract

According to one aspect, an abrasive article includes a backing and an abrasive layer comprising shaped structures comprising abrasive particles and a binder, and an interlayer between the backing and the abrasive layer. The interlayer can have at least one of the following: an ILT ave of at least 4 microns, an ILT max of at least 5 microns, or an ILT min of at least 3 microns.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a backing,   an abrasive layer overlying the backing,
 the abrasive layer comprising a plurality of shaped structures comprising abrasive particles and a binder, 
   an interlayer between the backing and the abrasive layer, the interlayer comprising at least one of the following:
 an ILT ave  of at least 4 microns, 
 an ILT max  of at least 5 microns, or 
 an ILT min  of at least 3 microns. 
   
     
     
         2 . The abrasive article of  claim 1 , wherein the interlayer has an ILT ave  of at least 4 microns. 
     
     
         3 . The abrasive article of  claim 1 , wherein the interlayer has an ILT ave  of no greater than 40 microns. 
     
     
         4 . The abrasive article of  claim 1 , wherein the shaped structures comprise a height of at least 5 microns. 
     
     
         5 . The abrasive article of  claim 1 , wherein the shaped structures comprise a height of no greater than 50 microns. 
     
     
         6 . The abrasive article of  claim 1 , wherein the abrasive article comprises an average interlayer thickness to average structure height ratio of at least 1:10 and no greater than 5:1. 
     
     
         7 . The abrasive article of  claim 1 , wherein the abrasive particles comprise silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, or any combination thereof. 
     
     
         7 . The abrasive article of  claim 1 , wherein the backing comprises a polymeric film (for example, a primed film), such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), polyester film (e.g., polyethylene terephthalate), polyamide film, or cellulose ester film; metal foil; mesh; foam (e.g., natural sponge material or polyurethane foam or polyester foam or polyolefin foam or PVC foam or silicone foam); cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton or rayon); paper; vulcanized paper; vulcanized rubber; vulcanized fiber; nonwoven materials; a combination thereof. 
     
     
         8 . The abrasive article of  claim 1 , wherein the backing comprises foam. 
     
     
         9 . The abrasive article of  claim 1 , wherein the backing comprises polyurethane foam. 
     
     
         10 . The abrasive article of  claim 1 , wherein the abrasive article comprises a coat weight, wherein the coat weight comprises the weight of the interlayer and the abrasive layer, wherein the coat weight is at least 15 g/m 2  and no greater than 100 g/m 2 . 
     
     
         11 . The abrasive article of  claim 1 , further comprising a tie layer underlying the inter layer. 
     
     
         12 . The abrasive article of claim  12 , wherein the tie layer comprises an elastic modulus of at least 1×10 4  Pa to no greater than 5×10 9  Pa. 
     
     
         13 . The abrasive article of  claim 12 , the tie layer comprises:
 an elastic modulus of:
 1) less than 1×10 6  Pa; 
 2) 1×10 4  to 1×10 6  Pa; or 
 3) 6×10 5  to 7×10 5 ; 
   a shaped structure height of 15-25 microns;   and either:
 a) A coat weight of at least 25 g/m 2  or at least 30 g/m 2  or at least 35 g/m 2  or at least 40 g/m 2  or at least 50 g/m 2  or at least 60 g/m 2 ; or 
 b) An ILT ave  of at least 7 microns. 
   
     
     
         15 . The abrasive article of  claim 12 , the tie layer comprises:
 an elastic modulus of less than 1×10 6  Pa;   a shaped structure height of 25-35 microns;   and either:
 a) A coat weight of at least 25 g/m 2 ; or 
 b) An ILT ave  of at least 14 microns. 
   
     
     
         16 . The abrasive article of  claim 12 , the tie layer comprises:
 an elastic modulus of at least 1×10 8  Pa;   a shaped structure height of 15-25 microns;   and either:
 a) A coat weight of at least 17 g/m 2  and not greater than 75 g/m 2 ; or 
 b) An ILT ave  of at least 6 microns and not greater than 17 microns. 
   
     
     
         17 . The abrasive article of  claim 12 , the tie layer comprises:
 an elastic modulus of at least 1×10 8  Pa;   a shaped structure height of 25-35 microns;   and either:
 a) A coat weight of at least 17 g/m 2  and not greater than 75 g/m 2 ; or 
 b) An ILT ave  of at least 5 microns and not greater than 11 microns. 
   
     
     
         14 . The abrasive article of  claim 12 , the tie layer comprises:
 an elastic modulus of at least 1×10 8  Pa;   a shaped structure height of 25-35 microns;   and either:
 a) A coat weight of at least 60 g/m 2 ; or 
 b) An ILT ave  of at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns. 
   
     
     
         15 . A method of making an abrasive article comprising:
 providing a backing;   depositing an interlayer and abrasive layer overlying the backing,
 the abrasive layer comprising a plurality of shaped structures comprising abrasive particles and a binder, 
   an interlayer between the backing and the abrasive layer, the interlayer comprising at least one of the following:
 an ILT ave  of at least 4 microns, 
 an ILT max  of at least 5 microns, or 
 an ILT min  of at least 3 microns. 
   
     
     
         16 . A method of using the abrasive article of  claim 1  to polish a workpiece, wherein the workpiece comprises an automotive clear coat, acrylic, paint, isocyanate, urethanes, polymeric layers, coatings.