Structured abrasive article with improved backing

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 backing can include a foam having a density of at least 50 kg/m 3 and not greater than 175 kg/m 3 .

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, wherein the backing comprises a foam having a density of at least 50 kg/m 3  and not greater than 175 kg/m 3 .   
     
     
         2 . The abrasive article of  claim 1 , wherein the interlayer has an ILT ave  of at least 4 microns or at least 4.5 microns. 
     
     
         3 . The abrasive article of  claim 1 , wherein the interlayer has an ILT ave  of no greater than 17 microns. 
     
     
         4 . The abrasive article of  claim 1 , wherein the shaped structures comprise pyramidal shapes. 
     
     
         5 . The abrasive article of  claim 1 , wherein the shaped structures comprise a height of at least 10 microns and 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. 
     
     
         7 . The abrasive article of  claim 1 , wherein the abrasive article comprises an average interlayer thickness to average structure height ratio of no greater than 5:1. 
     
     
         8 . The abrasive article of  claim 1 , wherein the backing comprises a density of at least at least 50 kg/m 3  and no greater than 175 kg/m 3 . 
     
     
         9 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a median particle size of at least 1 micron and no greater than 20 microns. 
     
     
         10 . 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. 
     
     
         11 . The abrasive article of  claim 1 , wherein the abrasive particles comprise silicon carbide. 
     
     
         12 . The abrasive article of  claim 1 , wherein the binder comprises a radiation curable binder. 
     
     
         13 . The abrasive article of  claim 1 , wherein the interlayer comprises interlayer particles and an interlayer binder. 
     
     
         14 . The abrasive article of  claim 13 , wherein the interlayer has the same composition as the abrasive layer. 
     
     
         15 . The abrasive article of  claim 13 , wherein the interlayer has a different composition than the abrasive layer. 
     
     
         16 . The abrasive article of  claim 1 , wherein the backing comprises foam. 
     
     
         17 . 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 17 g/m 2  and no greater than 75 g/m 2 . 
     
     
         18 . The abrasive article of  claim 1 , further comprising a tie layer underlying the inter layer. 
     
     
         19 . 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,   wherein the backing comprises a foam having a density of at least 50 kg/m 3  and not greater than 175 kg/m 3 .   
     
     
         20 . A method of using the abrasive article  claim 1 , to polish a workpiece, wherein the workpiece comprises an automotive clear coat, acrylic, paint, isocyanate, urethanes, polymeric layers, or coatings.