Method of making coated abrasive articles and coated abrasive articles

Abstract

A method of making a coated abrasive article, the method comprising: disposing a precursor make layer on a major surface of a backing, optionally partially curing the precursor make layer to provide a partially cured precursor make layer, disposing abrasive particles; partially embedding the abrasive particles in the optionally partially cured precursor make layer; and further curing the optionally partially cured precursor make layer to form a make layer. The precursor make layer comprises a component comprising: a) 50 wt% to 97.99 wt% of a phenol-formaldehyde resin; b) 1 wt% to 49 wt% of a resorcinol-formaldehyde resin; c) 1 wt% to 49 wt% of at least one compound having at least one free-radically polymerizable group; and d) 0.01 wt% to 1 wt% of a free-radical initiator. A size layer and / or a top size layer can be disposed on the make layer and abrasive article. Also disclosed are coated abrasive articles made by the method.

Description

Technical Field

[0001] This disclosure broadly relates to coated abrasive articles and methods of their preparation and use. Background Technology

[0002] Generally, coated abrasive articles have an abrasive layer fixed to a backing. The abrasive layer contains abrasive particles and a binder that fixes the abrasive particles to the backing. One type of coated abrasive article has an abrasive layer consisting of a primer layer and abrasive particles. In preparing such a coated abrasive article, a precursor primer layer containing a curable precursor primer layer is applied to the main surface of the backing. The abrasive particles are then at least partially embedded in the curable primer resin (e.g., by electrostatic coating), and the curable precursor primer layer is allowed to cure sufficiently to adhere the abrasive particles to the backing. Typically, a precursor re-adhesive layer containing a curable re-adhesive resin is then applied onto the at least partially cured curable primer resin and abrasive particles, followed by curing of the curable re-adhesive resin precursor, and optionally additional curing of the curable primer resin. Some coated abrasive articles also have a topcoat layer disposed on the primer layer and / or re-adhesive layer of the coated abrasive article. The topcoat layer typically includes a grinding aid and / or a load-bearing material.

[0003] A common practice in the abrasives industry is to add UV-curable resins to phenolic precursor primer formulations. By irradiating the precursor primer with UV light before coating the abrasive particles (hereinafter also referred to as "minerals"), the precursor primer is partially gelled, thus allowing for better control of mineral penetration into the precursor primer, resulting in improved mineral orientation.

[0004] This method may pose a challenge for some lamps that emit significant amounts of heat in addition to ultraviolet light. Exposure to these light sources can cause the phenolic resin to cure / dry prematurely, particularly forming a skin on its exposed surface. In such cases, even if the minerals adhere together, it cannot easily embed into the precursor primer layer. Summary of the Invention

[0005] Advantageously and unexpectedly, the method for preparing coated abrasive articles according to this disclosure can improve the pickup and retention of abrasive particle orientation during the electrostatic deposition of abrasive particles.

[0006] In a first aspect, this disclosure provides a method for preparing coated abrasive articles, the method comprising:

[0007] Provide a backing having a first primary surface and a second primary surface that are opposite each other;

[0008] A precursor primer layer is disposed on a first main surface of the backing, wherein the precursor primer layer comprises a partially cured reaction product having the following components:

[0009] a) 50% to 97.99% by weight of phenol-formaldehyde resin;

[0010] b) 1% to 49% by weight of resorcinol-formaldehyde resin;

[0011] c) 1% to 49% by weight of at least one compound having at least one free radical polymerizable group;

[0012] d) 0.01% to 1% by weight of a free radical initiator; and

[0013] e) Optional filler,

[0014] Wherein the weight percentage of components a) to d) is based on the combined weight of components a) to d); and

[0015] Optionally partially cure the precursor primer layer to provide a partially cured precursor primer layer; and

[0016] Abrasive particles are partially embedded in an optionally partially cured precursor primer layer; and the optionally partially cured precursor primer layer is further cured to provide a further cured precursor primer layer.

[0017] In a second aspect, this disclosure provides coated abrasive articles prepared according to the method of this disclosure.

[0018] As used in this article:

[0019] "(Meth)acryloyl" refers to a methacryloyl group and / or an acryloyl group (i.e., and / or ;as well as

[0020] "Weight %" and "Weight Percentage" are interchangeable.

[0021] The features and advantages of this disclosure will be further understood upon consideration of the specific embodiments and the appended claims. Attached Figure Description

[0022] Figure 1 A schematic side view of an exemplary abrasive article 100 prepared according to a method of the present disclosure.

[0023] Figure 2 A schematic side view of an exemplary abrasive article 100 prepared according to a method of the present disclosure.

[0024] It should be understood that those skilled in the art can devise many other modifications and embodiments that fall within the scope and spirit of this disclosure. The accompanying drawings may not be drawn to scale. Detailed Implementation

[0025] Figure 1 An exemplary abrasive article that can be prepared according to embodiments of the present disclosure is shown. The coated abrasive article 100 includes a backing 110 having opposing first main surfaces 112 and second main surfaces 114, and a primer layer 120 disposed on the first main surface 112. Abrasive particles 130 are partially embedded in and fixed within the primer layer 120. An optional top adhesive layer 150 is disposed on the primer layer 120 and the abrasive particles 130.

[0026] like Figure 1 The coated abrasive article shown can be prepared according to the method described below.

[0027] In the first step, a backing is provided. The backing has opposing first and second main surfaces. For example, available backings include those known in the art for preparing coated abrasive articles. Typically, the backing has two opposing main surfaces, but this is not mandatory. The thickness of the backing is typically in the range of about 0.02 mm to about 5 mm, advantageously in the range of about 0.05 mm to about 2.5 mm, and more advantageously in the range of about 0.1 mm to about 1.0 mm, but thicknesses outside these ranges may also be used. Generally, the strength of the backing should be sufficient to resist tearing or other damage during the grinding process. The thickness and smoothness of the backing should also be suitable for providing the desired thickness and smoothness of the coated abrasive article; for example, according to the intended application or use of the coated abrasive article.

[0028] Exemplary backings include: dense nonwoven fabrics (e.g., needle-punched, melt-spun, spunbond, spunlace, or melt-blown nonwoven fabrics), mesh, knitted fabrics, stitch-knitted fabrics, and / or woven fabrics; loose fabrics; polymer films; vulcanized fibers; paper; their treated forms; and combinations of two or more of these materials.

[0029] The fabric backing can be made from any known fiber, whether natural, synthetic, or a blend of natural and synthetic fibers. Examples of available fiber materials include fibers or yarns comprising: polyesters (e.g., polyethylene terephthalate), polyamides (e.g., hexamethylene adipamide, polycaprolactam), polypropylene, acrylics (formed from acrylonitrile polymers), cellulose acetate, polyvinylidene chloride-vinyl chloride copolymers, vinyl chloride-acrylonitrile copolymers, graphite, polyimide, silk, cotton, flax, jute, or rayon. Available fibers can be natural materials or recycled or waste materials, for example, recovered from garment cutting, carpet manufacturing, fiber manufacturing, or textile processing. Available fibers can be homogeneous or composite materials such as bicomponent fibers (e.g., co-spun sheath-core fibers). Fibers can be stretched and crimped, but can also be continuous filaments, such as those formed by extrusion processes.

[0030] The backing can have any suitable basis weight; typically, it ranges from 25 g / m² to 1250 g / m², more typically from 25 g / m² to 300 g / m², and even more typically from 25 g / m² to 275 g / m². In many embodiments (e.g., grinding belts and grinding discs), the backing typically has good flexibility; however, this is not necessary (e.g., vulcanized fiber discs). To promote adhesion of the adhesive resin to the backing, one or more surfaces of the backing can be modified by known methods, including corona discharge, ultraviolet light exposure, electron beam exposure, flame discharge, and / or texturing.

[0031] Optionally, the backing used in coated abrasive articles can be treated with one or more applied coating processes. Typical examples of backing treatments include an adhesive backing layer (i.e., a coating on the main surface of the backing opposite the abrasive layer), a pre-adhesive layer or adhesive layer (i.e., a coating disposed on the backing between the abrasive layer and the backing), and / or an impregnating agent saturating the backing. A semi-adhesive is similar to an impregnating agent, except that it is applied to a previously treated backing. Further details regarding backing treatments can be found, for example, in U.S. Patent Nos. 5,108,463 (Buchanan et al.), 5,137,542 (Buchanan et al.), 5,328,716 (Buchanan), and 5,560,753 (Buchanan et al.), the disclosure of which is incorporated herein by reference.

[0032] In the second step, a precursor primer layer is applied to the first main surface of the backing. The precursor primer layer can be applied by any known coating method for applying the primer layer to the backing, including methods such as, for example, roller coating, die extrusion coating, curtain coating, blade coating, concave coating, and spray coating.

[0033] The basis weight of the precursor primer and the resulting primer layer can depend on, for example, the intended use, the type of abrasive particles, and the properties of the coated abrasive particles being prepared, but will generally range from 1 g / m², 2 g / m², 5 g / m², 10 g / m², or 15 g / m² (gsm) to 20 gsm, 25 gsm, 100 gsm, 200 gsm, 300 gsm, 400 gsm, or even 600 gsm. The precursor primer can be applied by any known coating method for applying the precursor primer (e.g., primer coating) to the backing, including methods such as roll coating, die coating, curtain coating, blade coating, concave coating, and spray coating.

[0034] The precursor base layer comprises the following components, which include: a) 50% to 97.99% (preferably 50% to 89.99% by weight) of a phenol-formaldehyde resin; b) 1% to 49% (preferably 5% to 25% by weight) of a resorcinol-formaldehyde resin; c) 1% to 49% (preferably 5% to 30% by weight) of at least one compound having at least one free radical polymerizable group; d) 0.01% to 1% by weight of a free radical initiator; and e) optional filler, wherein the weight percentages of components a) to d) are based on the combined weight of components a) to d).

[0035] Examples of suitable phenol-formaldehyde resins (commonly referred to as "phenolic resins") include methyl phenolic resins and linear phenolic resins. In methyl phenolic resins, the molar ratio of formaldehyde to phenol is greater than or equal to 1, typically between 1.5 and 3.0. In linear phenolic resins, the molar ratio of formaldehyde to phenol is less than 1:1. A preferred phenol-formaldehyde resin has a molar ratio of formaldehyde to phenol of 1.5 to 2.1.

[0036] The phenolic resin is preferably a primary phenolic resin, or at least formaldehyde containing phenolic resin. Suitable alkaline catalysts for catalyzing the reaction between the aldehyde and phenolic components of the primary phenolic resin include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, and sodium carbonate, all of which are catalyst solutions dissolved in water.

[0037] Acetylated phenolic resins are typically coated as solutions containing water and / or organic solvents (e.g., alcohols). Typically, the solution contains about 50% to about 85% by weight of solids, but other concentrations can be used. If the solids content is very low, more energy is required to remove the water and / or solvent. If the solids content is very high, the resulting phenolic resin has excessively high viscosity, which often leads to processing problems.

[0038] Phenolic resins are well known and readily available from commercial sources. Examples of commercially available methyl phenolic resins that can be used to implement this disclosure include those sold by Durez Corporation under the trade name VARCUM (e.g., 29217, 29306, 29318, 29338, 29353); those sold by Ashland Chemical Co., Bartow, Florida under the trade name AEROFENE (e.g., AEROFENE 295); and those sold by Kangnam Chemical Company Ltd. of Seoul, South Korea under the trade name PHENOLITE (e.g., PHENOLITE TD-2207).

[0039] A review discussion of phenolic resins and their manufacture is given in the following reference: Kirk-Othmer, Encyclopedia of Chemical Technology, 4th Ed., John Wiley and Sons, 1996, New York, Vol.18, pp.603-644.

[0040] Resorcinol-formaldehyde resin can be described by the following chemical structure:

[0041]

[0042] Where m is a positive integer greater than or equal to one, or, in the case of mixtures, m may be a positive number greater than one. The resorcinol-formaldehyde resin is preferably a linear phenolic resorcinol-formaldehyde resin. Exemplary resorcinol-formaldehyde resins include those available under the trade name PENACOLITE from Sumitomo Chemical Advanced Technologies, Phoenix, Arizona, such as, for example, PENACOLITE R 20, PENACOLITE R 50, PENACOLITE R 2120, PENACOLITE R 2170, and PENACOLITE R 2200. A preferred resorcinol-formaldehyde resin is available under the trade name PENACOLITE R 50.

[0043] The inventors unexpectedly discovered that adding resorcinol-formaldehyde resin to a precursor primer layer comprising a methyl phenolic resin and a compound having at least one free-radical polymerizable group enhances its tackiness (especially after the optional polymerization of the free-radical polymerizable component), resulting in stronger adhesion and better orientation of the abrasive particles throughout the manufacturing process. Not wishing to be bound by theory, the inventors believe that the additional OH groups introduced by resorcinol-formaldehyde, relative to phenolic resin alone, lead to stronger intermolecular and intramolecular hydrogen bonds and also increase the resin's ability to retain moisture.

[0044] Examples of suitable compounds having at least one radically polymerizable group include compounds having at least one radically polymerizable group selected from (meth)acrylates, (meth)acrylamide, other vinyl compounds, and combinations thereof. Available radically polymerizable compounds may comprise olefinically unsaturated compounds having one or more (e.g., one, two, three, four, or more) radically polymerizable groups.

[0045] Exemplary monomers having a free radical polymerizable group include (meth)acrylamide, (meth)acrylic acid, (meth)acrylonitrile, 2-(2-ethoxyethoxy)ethyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, N,N-dimethylaminoethyl (meth)acrylate, 2-phenoxyethyl (meth)acrylate, 2-phenylethyl (meth)acrylate, caprolactone, cyclohexyl (meth)acrylate, dodecyl (meth)acrylate, ethoxylated phenoxyethyl (meth)acrylate, and (meth)propyl Tetrahydrofurfuryl acrylate, Hexyl methacrylate, Hydroxybutyl methacrylate, Hydroxyethyl methacrylate, Isobutyl methacrylate, Isopropyl methacrylate, Hydroxymethyl methacrylate, Hydroxypropyl methacrylate, Isobornyl methacrylate, Isobutyl methacrylate, Isodecyl methacrylate, Isononyl methacrylate, Isooctyl methacrylate, Lauryl methacrylate, Methyl methacrylate, N-(dodecyl(meth)acrylamide, N-(octadecyl)(meth)acrylamide, N-( tert-Ocyl(meth)acrylamide, n-butyl(meth)acrylate, n-decyl(meth)acrylate, n-dodecyl(meth)acrylate, n-hexyl(meth)acrylate, n-octyl(meth)acrylate, nonylphenol ethoxylated (meth)acrylate, N-substituted (meth)acrylamide, N-vinyl-2-pyrrolidone, N-vinylcaprolactam, 2-vinylpyridine, 4-vinylpyridine, octyl(meth)acrylate, phenyl(meth)acrylate, stearyl(meth)acrylate, styrene and substituted styrene, α-olefins (e.g., ethylene, propylene, butene, 1-hexene and 1-octene) ), tert-amyl methacrylate, tert-butyl methacrylate, tetrahydrofurfuryl methacrylate, tridecyl methacrylate, undecyl methacrylate, benzyl methacrylate, vinyl esters (e.g., vinyl acetate and butyl acetate), vinyl ethers (e.g., ethyl vinyl ether, propyl vinyl ether, butyl vinyl ether), vinyl chloride, vinylidene chloride, vinyltoluene, β-carboxyethyl methacrylate, 2-ethylhexyl methacrylate, 2-phenoxyethyl methacrylate, benzyl methacrylate, 2-phenylethyl methacrylate, C2-C 18Alkyl vinyl ethers, cyclohexyl (meth)acrylate, dodecyl (meth)acrylate, eicosyl (meth)acrylate, ethyl (meth)acrylate, dodecyl (meth)acrylate, heptadecanyl (meth)acrylate, hexadecyl (meth)acrylate, hexyl (meth)acrylate, isobornyl (meth)acrylate, isobutyl (meth)acrylate, isodecanyl (meth)acrylate, isononyl (meth)acrylate, isooctyl (meth)acrylate, lauryl (meth)acrylate, methyl (meth)acrylate, N-(n-dodecyl(meth)acrylamide), N-(tert-octyl)(meth)acrylamide, n-butyl (meth)acrylate, n-decyl (meth)acrylate, n-decyl (meth)acrylate, n-dodecyl (meth)acrylate, n-hexyl (meth)acrylate, n-octyl (meth)acrylate, nonadecanyl (meth)acrylate, ethoxylated nonylphenol (meth)acrylate, octyl (meth)acrylate, (meth)acrylate Pentadecyl acrylate, phenyl methacrylate, stearyl methacrylate, dimethylaminoethyl methacrylate, styrene and substituted styrene (e.g., styrene, α-methyl-styrene, 4-tert-butylstyrene and 4-chloromethylstyrene), tert-amyl methacrylate, tert-butyl methacrylate, tetradecyl methacrylate, tetrahydrofurfuryl methacrylate, tridecyl methacrylate, and undecyl methacrylate. Examples of suitable (meth)acrylates having more than one radically polymerizable group include di- and poly-(meth)acrylates and (meth)acrylamides, such as, for example, 1,2,4-butanetriol tri(meth)acrylate, 1,3-butanediol di(meth)acrylate, 1,3-propanediol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,4-cyclohexanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,6-Hexanediol monomethacrylate monoacrylate, alkoxylated cyclohexanediol dimethacrylate, alkoxylated hexanediol dimethacrylate, alkoxylated neopentyl glycol dimethacrylate, bis[1-(2-(meth)acryloyloxy)]-p-ethoxy-phenyl-dimethylmethane, bis[1-(3-(meth)acryloyloxy-2-hydroxy)]-p-propoxyphenyl-dimethylmethane, caprolactone-modified pentaerythritol hexamethacrylate, caprolactone-modified neopentyl glycol hydroxyneopentyl acrylate dimethacrylate, cyclohexanediol dimethacrylate, diethylene glycol dimethacrylate, pentaerythritol pentamethacrylate Ester, dipropylene glycol di(meth)acrylate, di(trimethylolpropane)tetra(meth)acrylate, ethoxylated (10) bisphenol A di(meth)acrylate, ethoxylated (20) trimethylolpropane tri(meth)acrylate, ethoxylated (3) bisphenol A di(meth)acrylate, ethoxylated (3) trimethylolpropane tri(meth)acrylate, ethoxylated (30) bisphenol A di(meth)acrylate, ethoxylated (4) bisphenol A di(meth)acrylate, ethoxylated (4) pentaerythritol tetra(meth)acrylate, ethoxylated (6) trimethylolpropane tri(meth)acrylate, ethoxylated (9) trimethylolpropane tri( Methacrylates, ethoxylated bisphenol A dimethacrylates, ethylene glycol dimethacrylates, glycerol trimethacrylates, hydroxy-neopentaldehyde modified trimethylolpropane dimethacrylates, neopentyl glycol dimethacrylates, pentaerythritol tetramethacrylates, pentaerythritol trimethacrylates, polyethylene glycol (200) dimethacrylates, polyethylene glycol (400) dimethacrylates, polyethylene glycol (600) dimethacrylates, propoxylated (3)propanetriyltrimethacrylates, propoxylated (3)trimethylolpropane trimethacrylates, propoxylated (5,5)propanetriyl... Trimethacrylates, propoxylated (6)-trimethylolpropane trimethacrylates, propoxylated neopentyl glycol dimethacrylates, sorbitan hexamethacrylates, tetraethylene glycol dimethacrylates, tricyclodecane-diethanol dimethacrylates, triethylene glycol dimethacrylates, trimethylolpropane trimethacrylates, tripropylene glycol dimethacrylates, tri(2-hydroxyethyl) isocyanurate trimethacrylates, methylene bis(meth)acrylamide, and poly(olefinically unsaturated) carbamoyl isocyanurates, such as those disclosed in U.S. Patent No. 4,648,843 (Mitra).

[0046] Examples of suitable free radical polymerizable vinyl compounds include diallyl phthalate, divinyl succinate, divinyl adipate, and divinyl phthalate.

[0047] Suitable free radical polymerizable compounds are available from a variety of commercial sources, such as Sartomer Co., Exton, Pennsylvania, or can be prepared by known methods.

[0048] If desired, water, organic solvents, and / or monofunctional free radical polymerizable compounds may be added to the precursor primer layer; for example, to reduce coating viscosity. Examples of monofunctional free radical polymerizable compounds include 2-phenoxyethyl (meth)acrylate, allyl (meth)acrylate, ethyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, isobornyl (meth)acrylate, isopropyl (meth)acrylate, methyl (meth)acrylate, n-hexyl (meth)acrylate, octadecyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, (meth)acrylamide, N,N-dimethylacrylamide, N-vinylpyrrolidone, and N-vinylcaprolactam.

[0049] Useful free radical initiators (i.e., initiators of free radical polymerization) may include thermal free radical initiators and photoinitiators.

[0050] Exemplary free radical thermal initiators may be used, including azo compounds (such as 2,2'-azobisisobutyronitrile (AIBN), 2,2'-azobis(2-methylbutyronitrile), 2,2'-azobis(2,4-dimethylpentanonitrile)) and peroxide compounds (such as benzoyl peroxide or lauroyl peroxide). Heat sources such as, for example, heated rollers, ovens, and heating lamps may be used to decompose any thermal initiator (if present).

[0051] Available free radical photoinitiators include those known to be suitable for photocuring free radical polyfunctional (meth)acrylates. Exemplary free radical photoinitiators include benzoin and its derivatives, such as α-methylbenzoin; α-phenylbenzoin; α-allylbenzoin; α-benzylbenzoin; benzoin ethers, such as benzoin dimethyl ketal, benzoin methyl ether, benzoin ethyl ether, benzoin n-butyl ether; acetophenone and its derivatives, such as 2-hydroxy-2-methyl-1-phenyl-1-propanone and 1-hydroxycyclohexylphenyl ketone; 2-methyl-1-[4-(methylthio)phenyl]-2-(4-morpholino)-1-propanone; 2-benzyl-2-(dimethylamino)-1-[4-(4-morpholino)phenyl]-1-butanone.

[0052] Other available free radical photoinitiators include pivaloin ethyl ether, anethole ethyl ether; anthraquinones, such as anthraquinone, 2-ethylanthraquinone, 1-chloroanthraquinone, 1,4-dimethylanthraquinone and 1-methoxyanthraquinone; benzophenone and its derivatives; iodonium and sulfonium salts of the substances described above; titanium complexes, such as bis([η]5-2,4-cyclopentadien-1-yl)bis[2,6-difluoro-3-(1H-pyrrolo-1-yl)phenyl]titanium; mono- and bis-acylphosphine and phosphine oxides (e.g., IGM resins from Waalwijk, The Netherlands, as OMNIRAD TPO, OMNIRAD TPO-L1800 and OMNIRAD 819).

[0053] Suitable photochemical radiation sources for decomposing photoinitiators are well known in the art and may include, for example, lasers, xenon flash lamps, microwave-driven lamps with H-type or D-type bulbs, medium-pressure mercury arc lamps, and light-emitting diode (LED) lamps.

[0054] The precursor base layer may optionally contain filler materials, diluted abrasive particles (e.g., as described below), or grinding aids, typically in the form of particulate materials. Typically, the particulate materials are inorganic. Examples of fillers that can be used in this disclosure include: metal carbonates (e.g., calcium carbonate (e.g., chalk, calcite, marl, travertine, marble, and limestone), calcium magnesium carbonate, sodium carbonate, magnesium carbonate), silicates (e.g., quartz, glass beads, glass bulbs, and glass fibers), silicates (e.g., talc, clay, (montmorillonite) feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminate, sodium silicate), metal sulfates (e.g., calcium sulfate, barium sulfate, sodium sulfate, sodium aluminum sulfate, aluminum sulfate), gypsum, vermiculite, wood flour, aluminum trihydrate, carbon black, metal oxides (e.g., calcium oxide (lime), aluminum oxide, titanium dioxide), and metal sulfites (e.g., calcium sulfite). If present, the amount of filler can be as high as 10%, 20%, 30%, 40%, or even 50% or more.

[0055] Grinding aids are materials that significantly influence the chemical and physical processes of grinding, thereby improving performance. Grinding aids encompass a wide variety of materials and can be inorganic- or organic-based. Examples of chemical groups in grinding aids include waxes, organohalides, halide salts, and metals, as well as alloys thereof. Organohalides typically decompose during grinding, releasing halogen acids or gaseous halides. Examples of such materials include chlorinated paraffins, such as naphthalene tetrachloride, naphthalene pentachloride, and polyvinyl chloride. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride, and magnesium chloride. Examples of metals include tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium.

[0056] Other miscellaneous grinding aids include sulfur, organosulfur compounds, graphite, and metal sulfides. Combinations of different grinding aids can be used, and in some cases, this can produce a synergistic effect.

[0057] The precursor base layer may also contain additives such as fibers, lubricants, wetting agents, surfactants, pigments, dyes, antistatic agents (e.g., carbon black, vanadium oxide, and / or graphite), coupling agents (e.g., silanes, titanates, and / or zirconate aluminates), plasticizers, suspending agents, etc. The amounts of these optional additives are selected to provide preferred properties.

[0058] After the precursor primer layer is coated onto the main surface of the backing, it is optionally (but preferably) heated and / or irradiated with photochemical radiation to induce polymerization of a free-radical polymerizable compound. This method partially cures the precursor primer layer and helps maintain the orientation of the abrasive particles during deposition.

[0059] Abrasive particles can be deposited onto the precursor primer layer (whether partially cured or not) by any method known in the field of abrasives, for example. Examples include drop coating, electrostatic coating, magnetic coating, and transfer from production tools, as described in U.S. Patent Nos. 10,611,001 (Adefri et al.) and 9,776,302 (Keipert, Cyprus).

[0060] The abrasive particles available can be the result of a pulverizing operation (e.g., pulverized abrasive particles already classified according to shape and size) or a forming operation (i.e., shaped abrasive particles), wherein the abrasive precursor material is shaped (e.g., molded), dried, and transformed into a ceramic material. A combination of pulverized abrasive particles and forming abrasive particles can also be used. Abrasive particles can be in the form of, for example, single particles, agglomerates, composite particles, and mixtures thereof.

[0061] The abrasive particles should have sufficient hardness and surface roughness to function as pulverizing abrasive particles in the grinding process. Preferably, the abrasive particles have a Mohs hardness of at least 4, at least 5, at least 6, at least 7, or even at least 8.

[0062] Suitable abrasive particles include, for example, pulverized abrasive particles comprising: molten alumina, heat-treated alumina, white molten alumina, ceramic alumina materials (such as ceramic alumina materials commercially available from 3M Company, St. Paul, Minnesota as 3M CERAMIC ABRASIVE GRAIN), brown alumina, blue alumina, silicon carbide (including green silicon carbide), titanium diboride, boron carbide, tungsten carbide, garnet, titanium carbide, diamond, cubic boron nitride, garnet, molten alumina-zirconia, iron oxide, chromium oxide, zirconium oxide, titanium dioxide, tin oxide, quartz, feldspar, flint, corundum, ceramics prepared by the sol-gel method (e.g., α-alumina), and combinations thereof. Examples of abrasive particles prepared by a sol-gel method from which abrasive particles can be separated, and methods for preparing such particles, can be found in U.S. Patents 4,314,827 (Leitheiser et al.), 4,623,364 (Cottringer et al.), 4,744,802 (Schwabel), 4,770,671 (Monroe et al.), and 4,881,951 (Monroe et al.). It is also contemplated that the abrasive particles may comprise abrasive agglomerates, such as those described, for example, in U.S. Patent Nos. 4,652,275 (Bloecher et al.) or 4,799,939 (Bloecher et al.). In some embodiments, the abrasive particles may be surface-treated with a coupling agent (e.g., an organosilane coupling agent) or otherwise physically treated (e.g., iron oxide or titanium oxide) to enhance the adhesion of the pulverized abrasive particles to the binder. Abrasive particles can be treated before they are bonded to the binder, or they can be surface-treated in situ by incorporating a coupling agent into the binder.

[0063] Preferably, the abrasive particles (and especially abrasive particles) comprise ceramic abrasive particles, such as polycrystalline α-alumina particles prepared, for example, by a sol-gel method. Ceramic pulverizing abrasive particles composed of microcrystals of α-alumina, magnesium aluminum spinel, and rare earth hexaaluminates can be prepared using sol-gel α-alumina particle precursors according to methods described, for example, in U.S. Patent No. 5,213,591 (Celikkaya et al.) and U.S. Patent Application Publication Nos. 2009 / 0165394 A1 (Culler et al.) and 2009 / 0169816 A1 (Erickson et al.). Further details regarding methods for preparing sol-gel derived abrasive particles can be found, for example, in U.S. Patent Nos. 4,314,827 (Leitzer), 5,152,917 (Pieper et al.), 5,435,816 (Spurgeon et al.), 5,672,097 (Hoopman et al.), 5,946,991 (Hoopman et al.), 5,975,987 (Hoopman et al.), and 6,129,540 (Hoopman et al.), as well as U.S. Patent Application Publication 2009 / 0165394 A1 (Kaller et al.).

[0064] In some preferred embodiments, the available abrasive particles (particularly in the case of abrasive particles) can be shaped abrasive particles, as seen in U.S. Patent Nos. 5,201,916 (Berg), 5,366,523 (Rowenhorst (Re 35,570)), and 5,984,988 (Berg). U.S. Patent No. 8,034,137 (Erickson et al.) describes alumina abrasive particles that have been shaped to a specific form and then crushed to form fragments that retain a portion of their initial shape characteristics. In some embodiments, the abrasive particles are precisely shaped (i.e., the shape of the particles is at least partially determined by the shape of the cavities in the production tools used to prepare them). Details regarding such abrasive particles and methods for their preparation can be found, for example, in U.S. Patent Nos. 8,142,531 (Adefris et al.), 8,142,891 (Kaller et al.), 8,142,532 (Erickson et al.), and 9,771,504 (Adefris); and U.S. Patent Application Publications 2012 / 0227333 (Adefris et al.), 2013 / 0040537 (Schwabel et al.), and 2013 / 0125477 (Adefris). A particularly useful shape for precisely forming abrasive particles is a lamellar shape with three sidewalls, any one of which can be straight or concave, and can be perpendicular or inclined relative to the lamellar base; for example, shapes as described in the references cited above.

[0065] Surface coatings on abrasive particles can be used to improve adhesion between the abrasive particles and the binder material, or to facilitate electrostatic deposition of the abrasive particles. In one embodiment, the surface coating described in U.S. Patent 5,352,254 (Silicaia) may be used in an amount of 0.1% to 2% of the weight of the abrasive particles. Such surface coatings are described in U.S. Patent Nos. 5,213,591 (Silicaia et al.), 5,011,508 (Wald et al.), 1,910,444 (Nicholson), 3,041,156 (Rowse et al.), 5,009,675 (Kunz et al.), 5,085,671 (Martin et al.), 4,997,461 (Markhoff-Matheny et al.), and 5,042,991 (Kunz et al.). Additionally, the surface coating can prevent the shaped abrasive particles from being capped. "Capping" is a term describing the phenomenon where metal particles from the workpiece being ground are welded to the top of the abrasive particles. Surface coatings that perform the above function are known to those skilled in the art.

[0066] In some implementations, the length and / or width of the abrasive particles may be selected to be in the range of 0.1 micrometers to 3.5 millimeters (mm), more typically in the range of 0.05 mm to 3.0 mm, and more typically in the range of 0.1 mm to 2.6 mm, but other lengths and widths may also be used.

[0067] Abrasive particles with a thickness ranging from 0.1 micrometers to 1.6 millimeters, more typically from 1 micrometer to 1.2 millimeters, can be selected, but other thicknesses are also possible. In some embodiments, the abrasive particles may have an aspect ratio (the ratio of length to thickness) of at least 2, 3, 4, 5, 6, or greater.

[0068] Abrasive particles can be independently classified by size according to industry-recognized grading standards. Exemplary industry-recognized grading standards include those issued by ANSI (American National Standards Institute), FEPA (Federation of European Abrasive Manufacturers), and JIS (Japanese Industrial Standards). Such industry-accepted grading standards include, for example: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 30, ANSI 36, ANSI 40, ANSI 50, ANSI 60, ANSI 80, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600; FEPA P8, FEPA P12, FEPA P16, FEPA P24, FEPA P30, FEPA P36, FEPA P40, FEPA P50, FEPA P60, FEPA P80, FEPA P100, FEPA P120, FEPA P150, and FEPA P80. P180, FEPAP220, FEPA P240, FEPA P320, FEPA P400, FEPA P500, FEPA P600, FEPA P800, FEPA P1000, FEPA P1200; FEPA F8, FEPA F12, FEPA F16, and FEPA F24; and JIS 8, JIS 12, JIS 16. JIS24, JIS 36, JIS 46, JIS 54, JIS 60, JIS 80, JIS 100, JIS 150, JIS 180, JIS 220, JIS 240, JIS 280, JIS 320, JIS 360, JIS 400, JIS 600, JIS 800, JIS 1000、JIS JIS 1500, JIS 2500, JIS 4000, JIS 6000, JIS 8000, and JIS 10,000. More typically, the sizes of pulverized alumina particles and alumina-based abrasive particles prepared by the seedless sol-gel method are independently set to ANSI 60 and 80 or FEPA F36, F46, F54, and F60 or FEPA P60 and P80 grading standards.

[0069] Alternatively, the abrasive particles may be tested using ASTM E-11, "Standard Specification for Wire Cloth and Sieves for Testing Purposes." ASTM E-11 specifies the design and construction requirements for test sieves that use a medium of woven wire mesh mounted in a frame to classify materials according to a specified particle size. -18+20 is a typical designation, meaning that shaped abrasive particles can pass through an ASTM E-11 18-mesh test sieve but may remain on an ASTM E-11 20-mesh test sieve. In one embodiment, the shaped abrasive particles have a particle size such that most particles pass through an 18-mesh test sieve and may remain on 20, 25, 30, 35, 40, 45, or 50-mesh test sieves. In various implementations, the shaped abrasive particles may have nominal sizing grades including: -18+20, -20+25, -25+30, -30+35, -35+40, -40+45, -45+50, -50+60, -60+70, -70+80, -80+100, -100+120, -120+140, -140+170, -170+200, -200+230, -230+270, -270+325, -325+400, -400+450, -450+500, or -500+635. Alternatively, custom mesh sizes such as -90+100 may be used.

[0070] Blends of different abrasive particles can be used.

[0071] Once the abrasive particles are coated onto the precursor primer layer, they are further cured to a point at least sufficient to hold the abrasive particles substantially on the primer layer for the remainder of the manufacturing process.

[0072] In some embodiments, a topcoat layer is applied to at least partially cured precursor base coat and abrasive particles. If present, the topcoat layer typically has a basis weight of 5 g / m² to 1100 g / m², preferably 50 g / m² to 700 g / m², and more preferably 250 g / m² to 600 g / m², but is not required to do so.

[0073] The topcoat layer can be applied in the form of pure water and / or organic solvents, or in the form of substances other than water and / or organic solvents. In some embodiments, the topcoat layer is formed by curing a precursor topcoat layer. Available precursor topcoats may include, for example, urea-formaldehyde resins, phenolic resins (linear phenolic resins and / or methyl phenolic resins), epoxy resins, or combinations thereof. Additional components in the topcoat layer may include waxes, mineral oils, grinding aids, and combinations thereof. Typically, the topcoat layer also contains at least one grinding aid, however, this is not mandatory.

[0074] Grinding aids are materials that significantly influence the chemical and physical processes of grinding, thereby improving performance. Grinding aids encompass a wide variety of materials and can be inorganic or organic-based. Examples of chemical groups in grinding aids include waxes, organohalides, halide salts, metals and their alloys, and stearates and metal salts of stearates. Organohalides typically decompose during grinding, releasing halogen acids or gaseous halides. Examples of such materials include chlorinated paraffins, such as naphthalene tetrachloride, naphthalene pentachloride, and polyvinyl chloride. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride, and magnesium chloride. Examples of metals include tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Other miscellaneous grinding aids include sulfur, organosulfur compounds, graphite, and metal sulfides. Combinations of different grinding aids can be used, and in some cases, this can produce a synergistic enhancing effect.

[0075] Figure 2 An exemplary abrasive article that can be prepared according to embodiments of the present disclosure is shown. The coated abrasive article 200 includes a backing 210 having opposing first main surfaces 212 and second main surfaces 214, and a base coat 220 disposed on the first main surfaces 212. Abrasive particles 230 are partially embedded in and fixed within the base coat 220. A top coat 240 is disposed on the base coat 220 and the abrasive particles 130. An optional top coat 250 is disposed on the top coat 240.

[0076] like Figure 2 The coated abrasive article shown can be manufactured according to the method described above, except that an optional top adhesive layer 150 (see...) Figure 1 The precursor adhesive layer is replaced by a top adhesive layer formed as follows: a precursor adhesive layer is disposed on a base adhesive layer (precursor), and the abrasive article is at least partially cured. A top adhesive layer is then optionally disposed on top of the top adhesive layer (e.g., as described above).

[0077] The precursor coating layer may be the same as or different from the precursor base coat layer. Examples of precursor coating layers may include free radical polymerizable monomers and / or oligomers, epoxy resins, acrylic resins, urethane resins, phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, amino plastic resins, cyanate ester resins, and combinations thereof.

[0078] The basis weight of the precursor primer and the resulting primer can depend on, for example, the intended use, the type of abrasive particles, and the properties of the coated abrasive particles being prepared, but will generally be in the range of 1 g / m², 2 g / m², 5 g / m², 10 g / m², or 15 g / m² (gsm) to 20 gsm, 25 gsm, 100 gsm, 200 gsm, 300 gsm, 400 gsm, or even 600 gsm. The precursor primer can be applied by any known coating method for applying the precursor primer (e.g., primer coating) to the backing, including, for example, roll coating, die coating, curtain coating, blade coating, concave coating, and spray coating.

[0079] Additional details regarding the (precursor) re-adhesive layer can be found in U.S. Patent No. 4,588,419 (Caul et al.), U.S. Patent No. 4,751,138 (Tumey et al.), and U.S. Patent No. 5,436,063 (Follett et al.).

[0080] The primer and topcoat layers, as well as their respective precursors, may also contain additives such as fibers, lubricants, wetting agents, surfactants, pigments, dyes, antistatic agents (e.g., carbon black, vanadium oxide, and / or graphite), coupling agents (e.g., silanes, titanates, and / or zirconate aluminates), plasticizers, suspending agents, etc. The amounts of these optional additives are selected to provide preferred properties. Coupling agents can improve adhesion to abrasive particles and / or fillers. The curable composition may be thermosetting, radiation-curing, or a combination thereof.

[0081] The coated abrasive articles according to this disclosure can be transformed into, for example, belts, rolls, discs (including perforated discs) and / or sheets. For belt applications, two free ends of an abrasive sheet can be joined together using known methods to form a spliced ​​belt.

[0082] Further details regarding coated abrasive articles and methods of their manufacture can be found, for example, in U.S. Patent Nos. 4,734,104 (Berg), 4,737,163 (Larkey), 5,203,884 (Buchanan et al.), 5,152,917 (Pipper et al.), 5,378,251 (Caller et al.), 5,436,063 (Follett et al.), 5,496,386 (Berg et al.), 5,609,706 (Benedict et al.), 5,520,711 (Helmin), 5,961,674 (Gagliardi et al.), and 5,975,988 (Christianson).

[0083] This disclosure selects an implementation scheme.

[0084] In a first embodiment, this disclosure provides a method for preparing coated abrasive articles, the method comprising:

[0085] Provide a backing having a first primary surface and a second primary surface that are opposite each other;

[0086] A precursor primer layer is disposed on a first main surface of the backing, wherein the precursor primer layer comprises a partially cured reaction product having the following components:

[0087] a) 50% to 97.99% by weight of phenol-formaldehyde resin;

[0088] b) 1% to 49% by weight of resorcinol-formaldehyde resin;

[0089] c) 1% to 49% by weight of at least one compound having at least one free radical polymerizable group;

[0090] d) 0.01% to 1% by weight of a free radical initiator; and

[0091] e) Optional filler,

[0092] Wherein the weight percentage of components a) to d) is based on the combined weight of components a) to d); and

[0093] Optionally partially cure the precursor primer layer to provide a partially cured precursor primer layer; and

[0094] Abrasive particles are partially embedded in an optionally partially cured precursor primer layer; and the optionally partially cured precursor primer layer is further cured to provide a further cured precursor primer layer.

[0095] In a second embodiment, this disclosure provides a method according to a first embodiment, wherein the component comprises:

[0096] a) 50% to 89.99% by weight of phenol-formaldehyde resin;

[0097] b) 5% to 25% by weight of resorcinol-formaldehyde resin;

[0098] c) 5% to 30% by weight of at least one compound having at least one radical-polymerizable group; and

[0099] d) 0.01% to 1% by weight of a free radical initiator; and

[0100] e) Optional filler,

[0101] The weight percentage of components a) to d) is based on the combined weight of components a) to d).

[0102] In a third embodiment, this disclosure provides a method according to a first or second embodiment, wherein the free radical initiator comprises a free radical photoinitiator.

[0103] In the fourth embodiment, this disclosure provides a method according to any one of the first to third embodiments, wherein a filler is present.

[0104] In a fifth embodiment, this disclosure provides a method according to any one of the first to fourth embodiments, the method further comprising placing a top adhesive layer on a further cured precursor under adhesive layer and abrasive particles.

[0105] In the sixth embodiment, this disclosure provides a method according to any one of the first to fourth embodiments, the method further comprising:

[0106] The precursor adhesive layer is applied onto the further cured precursor base layer and abrasive particles; and

[0107] The precursor adhesive layer is at least partially cured to provide an adhesive layer that is at least partially cured.

[0108] In a seventh embodiment, this disclosure provides a method according to a sixth embodiment, the method further comprising placing a top adhesive layer on a top adhesive layer that is at least partially cured.

[0109] In the eighth embodiment, this disclosure provides a coated abrasive article prepared by the method of the first embodiment.

[0110] In the ninth embodiment, this disclosure provides a coated abrasive article prepared by the method of the second embodiment.

[0111] In the tenth embodiment, this disclosure provides a coated abrasive article prepared by the method of the third embodiment.

[0112] In the eleventh embodiment, this disclosure provides a coated abrasive article prepared by the method of the fourth embodiment.

[0113] In the twelfth embodiment, this disclosure provides a coated abrasive article prepared by the method of the fifth embodiment.

[0114] In the thirteenth embodiment, this disclosure provides a coated abrasive article prepared by the method of the sixth embodiment.

[0115] In the fourteenth embodiment, this disclosure provides a coated abrasive article prepared by the method of the seventh embodiment.

[0116] The purposes and advantages of this disclosure are further illustrated by the following non-limiting embodiments, but the specific materials and quantities referenced in these embodiments, as well as other conditions and details, should not be construed as undue limitation of this disclosure.

[0117] Example

[0118] Unless otherwise stated, all other reagents were obtained or purchased from fine chemical suppliers such as Sigma-Aldrich Company, St. Louis, Missouri, or synthesized by known methods. Table 1 below reports the abbreviations of the materials used in the examples.

[0119] Unit abbreviations used in the examples: ℃ = degrees Celsius; cm = centimeter; mm = millimeter; µm = micrometer; kV = kilovolt; mJ / cm 2 = millijoules per square centimeter.

[0120]

[0121] Example 1

[0122] This embodiment was performed according to the following procedure: (1) 1.5 g of SAP was uniformly dispersed on a 4-inch × 8-inch (10.16 cm × 20.32 cm) mineral bed. (2) MR1 was scraped onto the coated side of the PRB (Paul N. Gardner Co., Pompano Beach, Florida) with a gap of 4 mils (102 microns) and an area slightly larger than the mineral bed. (3) The PRB was placed on a conveyor belt at 30 feet (9.1 m) / minute, with the MR1 coated side facing upwards and passing through a UV processor of FUSION UV Systems (Gaithersburg, Maryland) equipped with an H-type bulb. The UV light dose was: UVA - 242 mJ / cm². 2 UVB-167 mJ / cm 2 UVC-53 mJ / cm 2 UVV-mJ / cm 2 .

[0123] (4) Then place the PRB directly above the mineral bed, with the coating facing down towards the mineral. The gap between the PRB and the mineral bed is about 1 inch (2.54 cm). (5) Electrostatically coat the abrasive particles onto the MR1 layer using a DC electric field of 15 kV to 17 kV. (6) Place the coated product in an oven at 90°C for 30 minutes before mineral coating analysis.

[0124] Comparative Example A

[0125] Except for using MR2 instead of MR1 in step (2), this embodiment is carried out according to the procedure described in Embodiment 1.

[0126] Example 2

[0127] This embodiment was performed using the following steps: (1) 1.5 g of SAP was evenly dispersed on a 4-inch × 8-inch (10.16 cm × 20.32 cm) mineral bed. (2) MR1 was scraped onto the primer side of the PET, with a gap of 4 mils (102 microns), covering an area slightly larger than the mineral bed. (3) PRB was placed on a conveyor belt at 30 feet (9.1 m) / minute, with the MR1 coating facing upwards and passing through a UV processor from Radiance UV Systems equipped with an H-type bulb. The UV (UV) light dose was: UVA - 242 mJ / cm². 2 UVB-167 mJ / cm 2、 UVC-53 mJ / cm 2 UVV-mJ / cm 2 .

[0128] (4) Then place the PET directly above the mineral bed, with the coated side facing down towards the mineral. The gap between the PET and the mineral bed is approximately 1 inch (2.54 cm). (5) Electrostatically coat the mineral onto the MR1 layer using a DC electric field of 15 kV to 17 kV. (6) Before mineral coating analysis, place the coated sample in an oven at 90°C for 30 minutes.

[0129] Comparative Example B

[0130] Except for the use of MR2 instead of MR1 in step (2), this embodiment is generally carried out according to the procedure described in embodiment 2.

[0131] Mineral Coating Analysis

[0132] For Examples 1 and 2 and Comparative Examples A and B, the abrasive particles remaining on the mineral bed were weighed after coating to determine the amount of abrasive particles (i.e., minerals) picked up and incorporated into the coated abrasive article. The results of mineral picking are reported in Table 2 below.

[0133]

[0134] Images were captured using a Keyence microscope for mineral density and orientation analysis. The magnified area of ​​the image was 11.830 mm × 8.877 mm for density calculations. For example, the peak density was equal to the peak count in the image divided by the magnified area. For peak count analysis, only SAPs with an overall triangular shape were considered. Peaks were defined as SAPs with a dihedral angle greater than 45° to the background that were upright, while SAPs with a dihedral angle less than 45° were considered to be lying down. The mineral orientation ratio was calculated as peak density divided by SAP density. The results are reported in Table 3 below.

[0135]

[0136] All references, patents, and patent applications cited in this application are incorporated herein by reference in a consistent manner. In the event of any inconsistency or contradiction between the incorporated references and this application, the information in this application shall prevail. The foregoing description, given to enable those skilled in the art to practice this disclosure protected by the claims, should not be construed as limiting the scope of this disclosure, which is defined by the claims and all their equivalents.

Claims

1. A method for preparing coated abrasive articles, the method comprising: Provide a backing having a first primary surface and a second primary surface that are opposite each other; A precursor primer layer is disposed on the first main surface of the backing, wherein the precursor primer layer comprises a partially cured reaction product having the following components: a) 50% to 97.99% by weight of phenol-formaldehyde resin; b) 1% to 49% by weight of resorcinol-formaldehyde resin; c) 1% to 49% by weight of at least one compound having at least one free radical polymerizable group; d) 0.01% to 1% by weight of free radical initiator; as well as e) Optional filler, The weight percentage of components a) to d) is based on the combined weight of components a) to d); and Optionally, the precursor primer layer is partially cured to provide a partially cured precursor primer layer; as well as Abrasive particles are partially embedded in a precursor primer layer that is optionally partially cured; And further cure the optionally partially cured precursor primer layer to provide a further cured precursor primer layer.

2. The method according to claim 1, wherein the component comprises: a) 50% to 89.99% by weight of phenol-formaldehyde resin; b) 5% to 25% by weight of resorcinol-formaldehyde resin; c) 5% to 30% by weight of at least one compound having at least one free radical polymerizable group; as well as d) 0.01% to 1% by weight of free radical initiator; as well as e) Optional filler, The weight percentage of components a) to d) is based on the combined weight of components a) to d).

3. The method according to claim 1 or 2, wherein the free radical initiator comprises a free radical photoinitiator.

4. The method according to claim 1 or 2, wherein the filler is present.

5. The method according to claim 1 or 2, further comprising disposing a top adhesive layer on the further cured precursor base adhesive layer and the abrasive particles.

6. The method according to claim 1 or 2, further comprising: The precursor adhesive layer is applied to the further cured precursor base adhesive layer and the abrasive particles; as well as The precursor adhesive layer is at least partially cured to provide an at least partially cured adhesive layer.

7. The method of claim 6, further comprising disposing a top adhesive layer on the at least partially cured top adhesive layer.

8. A coated abrasive article prepared by the method according to claim 1.

9. A coated abrasive article prepared by the method according to claim 2.

10. A coated abrasive article prepared by the method according to claim 3.

11. A coated abrasive article prepared by the method according to claim 4.

12. A coated abrasive article prepared by the method according to claim 5.

13. A coated abrasive article prepared by the method according to claim 6.

14. A coated abrasive article prepared by the method according to claim 7.

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