Multilayer substrates and adhesive articles including a discontinuous polymeric layer, and methods of making same

Abstract

A multilayer substrate is provided. The multilayer substrate includes a mesh substrate having a discontinuous polymeric layer disposed on an exterior of a first major surface of the mesh substrate. The discontinuous polymeric layer provides a designed surface of the multilayer substrate. The discontinuous polymeric layer has a first major surface that is opposite the mesh substrate. Either: a) the first major surface of the discontinuous polymeric layer has a planar surface, in which the designed surface exhibits an average flatness of 50 micrometers or less; or b) the first major surface of the discontinuous polymeric layer includes a patterned structured surface. An abrasive article is also provided, including a multilayer substrate and abrasive particles of 36 to 3000 grade in size attached to the designed surface of the multilayer substrate and / or abrasive particles of 36 to 30000 grade in size distributed in the discontinuous polymeric layer of the multilayer substrate. Methods of making the multilayer substrates and abrasive articles are also provided.

Description

PA101811W002MULTILAYER SUBSTRATES AND ADHESIVE ARTICLES INCLUDING A DISCONTINUOUS POLYMERIC LAYER, AND METHODS OF MAKING SAMEBACKGROUND

[0001] Many abrasive articles are available for various abrading and polishing purposes. Further developments in articles and methods that employ fine grade abrasive particles would be desirable.SUMMARY

[0002] In a first aspect, a multilayer substrate is provided. The multilayer substrate comprises a mesh substrate having a first major surface and an opposing major surface; and a discontinuous polymeric layer disposed on an exterior of the first major surface. The discontinuous polymeric layer provides a designed surface of the multilayer substrate. The discontinuous polymeric layer has a first major surface that is opposite the mesh substrate, and either: a) the first major surface of the discontinuous polymeric layer comprises a planar surface, wherein the designed surface exhibits an average flatness of 50 micrometers or less; orb) the first major surface of the discontinuous polymeric layer comprises a patterned structured surface.

[0003] In a second aspect, an abrasive article is provided. The abrasive article comprises a multilayer substrate according to the first aspect; and at least one of: i) a plurality of first abrasive particles of 36 to 30000 grade in size attached to the designed surface; or ii) a plurality of second abrasive particles of 36 to 30000 grade in size distributed in the discontinuous polymeric layer.

[0004] In a third aspect, a method of making a multilayer substrate is provided. The method comprises applying a liquid polymeric composition on a first major surface of a mesh substrate; pressing a solid substrate against the coated mesh substrate; and curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface. The discontinuous polymeric layer provides a designed surface of the multilayer substrate. Either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

[0005] In a fourth aspect, a method of making a multilayer substrate is provided. The method comprises applying a liquid polymeric composition on a first major surface of a solid substrate; pressing a mesh substrate against the coated solid substrate; and curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface. The discontinuous polymeric layer provides a designed surface of the multilayer substrate. Either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

[0006] In a fifth aspect, a method of making an abrasive article is provided. The method comprises obtaining the multilayer substrate according to the first aspect; and attaching a plurality of first abrasive particles of 36 to 30000 grade in size to the designed surface.

[0007] In a sixth aspect, a method of making an abrasive article is provided. The method comprises making a multilayer substrate according to the method according to the third aspect, in which the liquid polymeric composition comprises at least one mineral distributed in a polymeric matrix. Additionally, the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer. Further, the mineral comprises a plurality of second abrasive particles of 36 to 30000 grade in size and comprising fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof.

[0008] In a seventh aspect, another method of making an abrasive article is provided. The method comprises applying a liquid polymeric composition on a first major surface of a mesh substrate, the liquid polymeric composition comprising at least one mineral distributed therein. The method further comprises pressing a solid substrate against the coated mesh substrate, wherein the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer. Additionally, the method comprises curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate.

[0009] It has been discovered that it is possible to employ fine grade abrasive particles on a mesh substrate by applying a discontinuous polymeric layer to a major surface of the mesh substrate, enabling the use of mesh substrates that otherwise have a surface roughness that is greater than a particle size of the fine grade abrasive particles. Additionally, the multilayer substrate formed by incorporating the discontinuous polymeric layer with the mesh substrate may be useful for other purposes, e.g., as a pad that can be utilized with an abrasive slurry to polish a workpiece.

[0010] The above Summary is not intended to describe each illustrated embodiment or every implementation of the present certain exemplary embodiments of the present disclosure. The Drawings and the Detailed Description that follow more particularly exemplify certain preferred embodiments using the principles disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying figures, in which:

[0012] FIG. 1 is a scanning electron microscopy (SEM) image of an exemplary multilayer substrate;

[0013] FIG. 2A is a photograph of another exemplary multilayer substrate;

[0014] FIG. 2B is an SEM image of a portion of the multilayer substrate of FIG. 2A;

[0015] FIG. 3A is an SEM image of a further exemplary multilayer substrate;

[0016] FIG. 3B is an SEM image with higher magnification of a portion of the multilayer substrate of FIG. 3A;

[0017] FIG. 4A is an SEM image of an exemplary abrasive article;

[0018] FIG. 4B is a general schematic cross-sectional depiction of an exemplary abrasive article;

[0019] FIG. 4C is a general schematic cross-sectional depiction of another exemplary abrasive article;

[0020] FIG. 5 A is an SEM image of the exemplary abrasive article of Example 3;

[0021] FIG. 5B is an SEM image with higher magnification of a portion of the abrasive article of FIG.5 A;

[0022] FIG. 5C is an SEM image with higher magnification of a portion of the abrasive article of FIGS. 5A and 5B;

[0023] FIG. 6 is a flow chart of an exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0024] FIG. 7A is a general schematic cross-sectional depiction of a portion of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0025] FIG. 7B is a general schematic cross-sectional depiction of a portion of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0026] FIG. 7C is a general schematic cross-sectional depiction of a portion of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0027] FIG. 8A is a general schematic cross-sectional depiction of a portion of an additional exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0028] FIG. 8B is a general schematic cross-sectional depiction of a portion of an additional exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0029] FIG. 8C is a general schematic cross-sectional depiction of a portion of an additional exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0030] FIG. 8D is a general schematic cross-sectional depiction of a portion of an additional exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0031] FIG. 9 is a flow chart of a further exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0032] FIG. 10A is a general schematic cross-sectional depiction of a portion of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0033] FIG. 10B is a general schematic cross-sectional depiction of a portion of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0034] FIG. 10C is a general schematic cross-sectional depiction of a portion of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0035] FIG. 10D is a general schematic cross-sectional depiction of a portion of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0036] FIG. 11 A is a general schematic cross-sectional depiction of a portion of a still further exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0037] FIG. 1 IB is a general schematic cross-sectional depiction of a portion of a still further exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0038] FIG. 11C is a general schematic cross-sectional depiction of a portion of a still further exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0039] FIG. 1 ID is a general schematic cross-sectional depiction of a portion of a still further exemplary method of making a multilayer substrate, according to embodiments of the present disclosure;

[0040] FIG. 12 is a general schematic side view depiction of a roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure;

[0041] FIG. 13 is a general schematic side view depiction of another roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure;

[0042] FIG. 14 is a general schematic side view depiction of a further roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure;

[0043] FIG. 15 is a general schematic side view depiction of yet another roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure;

[0044] FIG. 16 is a flow chart of an exemplary method of making an abrasive article, according to embodiments of the present disclosure;

[0045] FIG. 17 is a perspective view of a Cartesian coordinate system of a surface that can be utilized to describe various surfaces of articles;

[0046] FIG. 18A illustrates a warp knit mesh substrate; and

[0047] FIG. 18B illustrates a warp knit mesh substrate with primary and secondary fibers indicated.

[0048] In the drawings, like reference numerals indicate like elements. While the above-identified drawings, which may not be drawn to scale, set forth various embodiments of the present disclosure, other embodiments are also contemplated, as noted in the Detailed Description. In all cases, this disclosure describes the presently disclosed disclosure by way of representation of exemplary embodiments and not by express limitations. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of this disclosure.DETAILED DESCRIPTION

[0049] For the following Glossary of defined terms, these definitions shall be applied for the entire application, unless a different definition is provided in the claims or elsewhere in the specification.Glossary

[0050] Certain terms are used throughout the description and the claims that, while for the most part are well known, may require some explanation. It should be understood that:

[0051] The term “liquid” as used herein refers to the state of matter that has a fixed volume but lacks a fixed shape;

[0052] The term “solid” as used herein with respect to a substrate refers to a nonporous material (e.g., layer or film);

[0053] The term “substrate” as used herein encompasses a variety of materials including sheets, films, solid layers, continuous layers, discontinuous layers, meshes, rolls, sleeves, liners, and belts. Substrates may have a known length, width, and / or surface area, or may have an indefinite length (e.g., a film / web that gets wound up on a roll);

[0054] The term “mesh” as used herein refers to a substrate that has a network of material (e.g., fibrous material) and open pores or voids;

[0055] The term “density” as used herein with respect to a mesh substrate refers to a mass of mesh material per cubic centimeter of the mesh material. A region with less density has more open space per cubic centimeter of mesh material than a region with greater density;

[0056] The term “designed surface” as used herein with respect to a multilayer substrate or an abrasive article refers to an area or volume of a polymeric material that has an intentionally engineered configuration at an exterior surface of the multilayer substrate or abrasive article, as opposed to a random or uncontrolled configuration;

[0057] The term “pattern” as used herein refers to a specific planned arrangement of a material, as opposed to a random or uncontrolled configuration of the material (e.g., a polymeric composition, a surface, etc.);

[0058] The term “discontinuous” as used herein with respect to a polymeric layer or pattern refers to having at least one gap or interval between adjacent portions of the polymeric layer or pattern;

[0059] The term “adjacent” as used herein when referring to two objects (e.g., fibers, polymeric material, etc.) means that the two objects are in proximity with one another. They may be in direct contact with one another or there may be intervening objects or open spaces / gaps between the two objects;

[0060] The terms “polymer” and “macromolecule” are used herein consistent with their common usage in chemistry of being composed of many repeated subunits, plus, the term “polymer” is used to describe the resultant material formed from a polymerization reaction;

[0061] The term “polymeric” is the adjective form of “polymer”;

[0062] The term “curing” as used herein with respect to a polymeric composition encompasses each of drying, solidifying, and polymerizing (e.g., of reactive components);

[0063] The term “average flatness” refers to an average measured difference in height between adjacent peaks of a discontinuous surface;

[0064] The term “planar” as used herein with respect to a surface refers to a surface lacking utilitarian features protruding from a two-dimensional plane of the surface;

[0065] The term “structured surface” as used herein with respect to a polymeric layer or substrate refers to the presence of utilitarian features protruding from a two-dimensional plane of the polymeric layer or substrate;

[0066] The term “abrasive particles” as used herein includes both individual abrasive grits and a plurality of individual abrasive grits bonded together to form an agglomerate;

[0067] The terms “about” or “approximately” with reference to a numerical value or a shape means + / - five percent of the numerical value or property or characteristic, but expressly includes the exact numerical value; and

[0068] The term “substantially” with reference to a property or characteristic means that the property or characteristic is exhibited to a greater extent than the opposite of that property or characteristic is exhibited.

[0069] As used in this specification and the appended embodiments, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference “a compound” includes a mixture of two or more compounds. As used in this specification and the appended embodiments, the term “or” is generally employed in its sense including “and / or” unless the content clearly dictates otherwise.

[0070] Unless otherwise indicated, all numbers expressing quantities or ingredients, measurement of properties and so forth used in the specification and embodiments are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached listing of embodiments can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings of the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claimed embodiments, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0071] Various exemplary embodiments of the disclosure will now be described. Exemplary embodiments of the present disclosure may take on various modifications and alterations without departing from the spirit and scope of the present disclosure. Accordingly, it is to be understood that the embodiments of the present disclosure are not to be limited to the following described exemplary embodiments but is to be controlled by the limitations set forth in the claims and any equivalents thereof.

[0072] With reference to FIG. 17, an article can be characterized in three-dimensional space by superimposing a Cartesian coordinate system onto its structure. A first reference plane 17224 is centered between major surfaces 17212 and 17214. First reference plane 17224, referred to as the y-z plane, has the x-axis as its normal vector. A second reference plane 17226, referred to as the x-y plane, extends substantially coplanar with surface 17216 and has the z-axis as its normal vector. A third reference plane 17228, referred to as the x-z plane, is centered between first end surface 17220 and second end surface 17222 and has the y-axis as its normal vector. Taking the article to be a mesh substrate, a first major surface of the mesh substrate corresponds to surface 17216 and is parallel to the x-y plane and orthogonal to the z-plane. A second opposing major surface of the mesh substrate corresponds to surface 17218 (and is also parallel to the x-y plane and orthogonal to the z-plane).

[0073] In some embodiments, the multilayered article includes a structured polymeric layer and the structured surfaces of the polymeric layer are three-dimensional on a macroscale. However, on a microscale (e.g., surface area that includes at least two adjacent structures with a valley or channeldisposed between the structures) the polymeric layer can be considered planar with respect to the structures. The width and length of the structures are in the x-y plane and the height of the structures is in the z-direction. Further, the polymeric layer is parallel to the x-y plane and orthogonal to the z-plane.

[0074] In some embodiments, the polymeric layer will be applied to the primary fibers of the mesh substrate such that the polymeric material pattern in the x-y plane will substantially match that of the mesh substrate primary fibers. In some embodiments, the polymeric layer applied to the mesh substrate will be entirely independent of, or only partially match, that of the primary fibers in the x-y plane. In these embodiments, the pattern and area coverage of the polymeric layer is controlled by the coating or patterning method utilized to deposit the polymeric layer, and the polymeric layer can connect across multiple primary fibers.

[0075] In a first aspect, a multilayer substrate is provided. The multilayer substrate comprises:

[0076] a mesh substrate having a first major surface and an opposing major surface; and

[0077] a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate, wherein the discontinuous polymeric layer has a first major surface that is opposite the mesh substrate; and

[0078] either:

[0079] a) wherein the first major surface of the discontinuous polymeric layer comprises a planar surface, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or

[0080] b) wherein the first major surface of the discontinuous polymeric layer comprises a patterned structured surface.

[0081] Referring to FIG. 1, a scanning electron microscopy (SEM) image is provided of an exemplary multilayer substrate 1000. The multilayer substrate 1000 comprises a mesh substrate 1100 having a first major surface 1110 and an opposing major surface (not shown), and a discontinuous polymeric layer 1200 disposed on an exterior 1112 of the first major surface 1110. The discontinuous polymeric layer 1200 provides a designed surface 1250 of the multilayer substrate 1000. In this case, the designed surface 1250 includes a series of undulating strips 1210, 1212, 1214, 1216, and 1218, of polymeric material 1205 disposed across the first major surface 1110 of the mesh substrate 1100. The adjacent strips of polymeric material 1205 are separated by gaps 1230, 1232, 1234, and 1236, which may be useful to help retain a porous nature of the mesh substrate 1100. As such, in some embodiments, a multilayer substrate comprises a plurality of gaps between adjacent portions of the discontinuous polymeric layer located between adjacent primary fibers of the mesh substrate.

[0082] It is to be understood that it is not necessary that the designed surface 1250 be perfectly formed, e.g., lacks any defects in the design of the discontinuous polymeric layer 1200. For instance, an area 1207 can be seen in FIG. 1 where polymeric material 1205 bridges two adjacent strips (1212 and 1214) of polymeric material 1205 of the discontinuous polymeric layer 1200. Additionally, several divots 1220 in an exterior surface 1209 of the polymeric strips (1210, 1212, 1214, 1216, and 1218) are present in the discontinuous polymeric layer 1200.

[0083] FIG. 2A is a photograph of another exemplary multilayer substrate 2000 comprising a mesh substrate 2100 having a first major surface 2110 and a discontinuous polymeric layer 2200 disposed on an exterior 2112 of the first major surface 2110. It is noted that the exterior 2252 of the overall designed surface 2250 of this multilayer substrate 2000 exhibits a shiny appearance. A closer view of the multilayer substrate 2000 can be seen FIG. 2B, which is an SEM image of a portion of the multilayer substrate 2000 of FIG. 2A. Like the multilayer substrate 1000 of FIG. 1, the designed surface 2250 includes a series of undulating strips 2210, 2212, 2214, 2216, and 2218, of polymeric material 2205 disposed across the first major surface 2110 of the mesh substrate 2100. The adjacent strips of polymeric material 2205 are separated by gaps 2230, 2232, 2234, and 2236. This particular portion of the multilayer substrate 2000 lacks the bridging of polymeric material 2205 between adjacent strips and also lacks divots in an exterior surface 2209 of the polymeric strips (2210, 2212, 2214, 2216, and 2218).

[0084] In some embodiments, the discontinuous polymeric layer of a multilayer substrate has a first major surface that is opposite the mesh substrate and that first major surface comprises a planar surface. In such cases, the designed surface preferably exhibits an average flatness of 50 micrometers or less, such as 45 micrometers, 40 micrometers, 35 micrometers, 30 micrometers, or even 25 micrometers or less. Average flatness may be determined by the following Raised Portion Topological Profile Method: The topological profile is determined using a Keyence VKX1100 confocal 3D measuring confocal microscope (Keyence Corporation, Osaka, Japan). A 4-inchby 4-inch swath of the combination is placed on the sample tray and a 10X magnification, with ring and axial lighting is used for the evaluation. The resulting image is analyzed using VK Series Analyzer Software (Keyence Corporation, Osaka, Japan). An associated height differential is determined by taking the elevation of the raised portion and the elevation of adjacent portions. Providing such an average flatness may be advantageous at least when using the multilayer substrate with fine grade abrasive particles.

[0085] Referring now to FIG. 3A, an SEM image is provided of an exemplary multilayer substrate 3000, comprising a mesh substrate 3100 having a first major surface 3110 and a discontinuous polymeric layer 3200 disposed on an exterior 3112 of the first major surface 3110. In this embodiment, a first major surface 3250 of the discontinuous polymeric layer 3200, which is opposite the mesh substrate 3100, comprises a patterned structured surface 3255. FIG. 3B is an SEM image that has a higher magnification of a portion of the multilayer substrate 3000 of FIG. 3 A. FIG. 3B provides a closer view of the patterned structured surface 3255, which includes a series of rows of linear prisms 3257 as the structures extending from a two-dimensional plane of the first major surface 3250 of the discontinuous polymeric layer 3200. As such, in some embodiments the discontinuous polymeric layer has a first major surface that is opposite the mesh substrate and that first major surface comprises a patterned structured surface.

[0086] The presence of a discontinuous polymeric layer may result in the multilayer substrate exhibiting a surface area of 20% or greater than the (e.g., same) mesh substrate alone, such as 25%, 30%, 35% or 40% or greater. This may be advantageous at least when the multilayer substrate is employed for abrasive purposes. In certain cases, the presence of a discontinuous polymeric layer may result in the multilayer substrate exhibiting a Young’s modulus that is at least 50% larger than the (e.g., same) meshsubstrate alone, such as 55%, 60%, 65%, 70%, or at least 75% larger. Young’s modulus is determined by mechanical testing, e.g., using an Instron (Norwood, MA) tensile testing machine in which the initial slope of force versus distance ranges from 0.2 to 20 mm. Providing a multilayer substrate that is stiffer than the mesh substrate may be advantageous at least when the multilayer substrate will be subjected to handling that requires employing a less flexible substrate.

[0087] In a second aspect, an abrasive article is provided. The abrasive article comprises:

[0088] a multilayer substrate according to any embodiment of the first aspect; and

[0089] at least one of: i) a plurality of first abrasive particles of 36 to 30000 grade in size attached to the designed surface; or ii) a plurality of second abrasive particles of 36 to 30000 grade in size distributed in the discontinuous polymeric layer.

[0090] Referring to FIG. 4A, an SEM image is provided of an exemplary abrasive article 4500. The abrasive article 4500 comprises a multilayer substrate 4000, comprising a mesh substrate 4100 having a first major surface 4110 and a discontinuous polymeric layer 4200 disposed on an exterior 4112 of the first major surface 4110. The discontinuous polymeric layer 4200 provides a designed surface 4250 of the multilayer substrate 4000. The abrasive article 4500 further comprises a plurality of (e.g., first) abrasive particles 4600 of 36 to 30000 grade in size attached to the designed surface 4250. In this case, the abrasive particles 4600 are attached using an adhesive 4620. In certain embodiments, the polymeric layer acts as an adhesive. In certain embodiments, an abrasive article further comprises a binder (e.g., a make coat) disposed on the designed surface, and the abrasive particles are at least partially embedded in the binder. Also optionally, the abrasive article may also include a size coat disposed on the plurality of abrasive particles.

[0091] Moreover, in some embodiments in which a size coat is present, a supersize coat may be present over the size coat. A supersize coat or layer, if present, is a coating applied on at least a portion of the size coat layer, and is generally added to provide, for example, a grinding aid, and / or as an anti-loading coating. Further, a supersize layer may prevent or reduce the accumulation of swarf (the material abraded from a workpiece) on the size coat or between abrasive particles and / or in and around apertures, which can dramatically reduce the cutting ability and / or the resulting workpiece finish provided by an abrasive article. Useful supersize layers include a grinding aid (e.g., potassium tetrafluoroborate) or metal salts of fatty acids (e.g., zinc stearate or calcium stearate). Other materials may be present in the supersize layer.

[0092] For instance, referring to FIG. 4B, a general schematic cross-sectional depiction is provided of an exemplary abrasive article 4500b. The abrasive article 4500b includes a mesh substrate 4100b having a discontinuous polymeric layer 4200b disposed thereon. The discontinuous layer 4200b has a gap 4230b between adjacent portions of polymeric material 4205b. In this case, the polymeric material 4205b has a structured surface 4255b, on top of which an optional binder 4630b is disposed. Optionally, abrasive particles 4600b can be included throughout the entirety of the polymeric material 4205b. A plurality of (e.g., first) abrasive particles 4600b are at least partially embedded in the binder 4630b. Further, an optional size coat 4640b is disposed over the plurality of abrasive particles 4600b and an optional supersize coat 4650b is disposed on the size coat 4640b opposite the binder 4630b.

[0093] Referring to FIG. 4C, a general schematic cross-sectional depiction is provided of another exemplary abrasive article 4500c. The abrasive article 4500c includes a mesh substrate 4100c having a discontinuous polymeric layer 4200c disposed thereon. The discontinuous layer 4200c has a gap 4230c between adjacent portions of polymeric material 4205c. In this case, the polymeric material 4205c has a planar surface, on top of which an optional binder 4630c is disposed. A plurality of (e.g., first) abrasive particles 4600c are at least partially embedded in the binder 4630c. Further, an optional size coat 4640c is disposed over the plurality of abrasive particles 4600c and an optional supersize coat 4650c is disposed on the size coat 4640c opposite the binder 4630c. Optionally, abrasive particles 4600c can be included throughout the entirety of the polymeric material 4205c.

[0094] In FIG. 5 A an SEM image of the exemplary abrasive article 5500 of Example 3 is provided. FIG. 5B is an SEM image with a higher magnification of the abrasive article 5500 of FIG. 5 A. Referring to FIGS. 5A and 5B, the abrasive article 5500 comprises a multilayer substrate 5000, comprising a mesh substrate 5100 having a first major surface 5110 and a discontinuous polymeric layer 5200 disposed on an exterior 5112 of the first major surface 5110. The discontinuous polymeric layer 5200 provides a designed surface 5250 of the multilayer substrate 5000. The abrasive article 5500 further comprises a plurality of (e.g., second) abrasive particles 5700 of 36 to 30000 grade in size distributed in the discontinuous polymeric layer 5200. Also in this embodiment, a first major surface 5260 of the discontinuous polymeric layer 5200 comprises a patterned structured surface 5255. FIG. 5C is an SEM image that provides a closer view of the patterned structured surface 5255 of a portion of the abrasive article 5500 of FIG. 5B (the portion indicated by the rectangle in FIG. 5B). The patterned structured surface 5255 includes a series of rows of linear prisms 5257 as the structures extending from a two- dimensional plane of the first major surface 5260 of the discontinuous polymeric layer 5200. Some of the abrasive particles 5700 can be seen on the patterned structured surface 5255.

[0095] Exemplary suitable materials for use in preparing multilayer substrates and abrasive articles are described in detail below.

[0096] Optionally, the mesh substrate comprises a net, a woven fabric, or a knitted fabric. When the mesh substrate is in a form of a net, it often comprises a plurality of each of primary fibers, secondary fibers, and tertiary fibers. The mesh substrate may be constructed from any of a number of materials known in the art for making coated abrasive articles. A mesh substrate can be distinguished from other fabrics based on the size of the holes formed therein. In at least one embodiment, the holes in the mesh substrate can be formed by the yams (if knitted or woven) or by the polymer vertical and horizontal strands (if extruded). The holes can be of varying size due to the nature of knitted articles. Advantageously, the holes may facilitate dust extraction when the mesh substrate is part of an abrasive article. In at least one embodiment, the mesh substrate can have an average size of 0.5 square millimeters. In at least one embodiment, the mesh substrate can have an open area of at least 40%, at least 50%, even at least 60%. In at least one embodiment, the mesh substrate can have an initial open area of between 40% and 60% (inclusive).

[0097] If the mesh substrate is a fabric (either woven fabric or knitted fabric), then the fabric can have the following properties. Various fabric mesh backings can be commercially available from Sitip S.p.A. (Cena, Italy) or Scott and Fyfe Ltd. (Tayport, UK). In at least one embodiment, the mesh substrate can have a yam thickness of at least 100 micrometers, at least 150 micrometers, at least 300 micrometers, or at least 350 micrometers. In another measurement, the yam can have a total denier of no greater than 3000 deniers, no greater than 1000 deniers, or no greater than 500 deniers. In at least one embodiment, the yam can have a breaking tenacity of at least X300 mN / tex as measured by ASTM D2256. The mesh substrate can also have a fabric weight of no greater than 300 gsm (gram per square meter), no greater than 220 gsm, or no greater than 120 gsm. The mesh substrate can have a fabric weight of at least 40 gsm.

[0098] In at least one embodiment, the mesh substrate can be mostly planar and a plane of mesh substrate can be established using a Kawabata evaluation system for surface friction and roughness. In at least one embodiment, the plane can be established based on a majority of surface area or cross-sectional area of a yam or other material in a single plane. For example, if a fabric has 50% of the solid surface area in a first plane, but 30% of the solid surface area in a second plane, then the first plane can be the reference plane. Thus, the loops (if knitted) can be raised relative to the reference plane. The reference plane can be generally parallel to a flat surface on which the mesh backing rests. In at least one embodiment, the plane of a woven fabric can be established by the weft. In at least one embodiment, the height differential between the raised portion and an adjacent portion can be at least 40, 50, or 60 micrometers.

[0099] If the mesh substrate is a woven fabric, then the mesh substrate can have at least 2 ends per inch and no greater than 20 ends per inch. A woven fabric mesh substrate can have raised portions defined by the picks of the woven fabric. For example, an overlap of a weft yam (or thread) with a warp yam (or thread) can form a pick that is raised above a plane of the woven fabric.

[0100] If the mesh substrate is a knitted fabric, then the mesh substrate can have no greater than 2 stitches per square inch. In at least one embodiment, the mesh substrate can be a warp knitted fabric. Specifically, tricot knits, such as half-tricot knits were found to have properties that work well as a net abrasive. In at least one embodiment, the warp knitted fabric can use closed laps that are formed by twisting one of the loops. A stitch or loop can include a head, two legs, and two feet which describes sections of a yam and is described further herein. In at least one embodiment, the head of the stitch and / or the feet of another stitch can form the raised portion of the mesh substrate. The raised portion can be at least two times the diameter of the yam thickness. In at least one embodiment, the warp knitted fabric can further include have a plurality of bobbles or knots formed in addition to the stitches or loops of the yam. For example, a first dimension of the raised portion can be at least two times the diameter of the yam thickness when stretched to 5% of the breaking tenacity for the yam according to ASTM D2256(2021).

[0101] Referring to FIG. 18A, a mesh substrate 18000 is depicted. This mesh substrate is a warp knit 18004 having a raised portion 18002. The warp knit 18004 includes alternating overlap (e.g., 18006)strands and underlap (e.g., 18008) strands. For instance, a warp knit is derived from two pieces intertwining with each other where one strand goes left to right then left again and so on while the other strand goes right to left then right again. In so doing, they hook into each other creating a “primary strand” and two “secondary strands”. Often, a warp knit is made of two parts. The first is a stitch which is formed by wrapping the yam around a needle and drawing it through the previous loop. The wrapping generates a ridge, referred to as an overlap. The two fibers that form the knit are called an underlap and an overlap where the overlap becomes the top surface. The first major surface of a mesh substrate according to certain embodiments of the present disclosure is optionally formed in this way. Referring to FIG. 18B, three “primary strands” 18010 and eight “secondary strands” 18020 are indicated on the mesh substrate of FIG. 18 A. ft is predominantly on the primary strands that a discontinuous polymeric layer is applied.

[0102] Although not necessarily so limited, a mesh substrate can have a thickness of at least 0.02 millimeters, at least 0.03 millimeters, 0.05 millimeters, 0.07 millimeters, or 0.1 millimeters; and a thickness of up to 5 millimeters, up to 4 millimeters, up to 2.5 millimeters, up to 1.5 millimeters, or up to 0.4 millimeters. The mesh substrate can be flexible and has void spaces (e.g., void spaces between strands) such that it is porous. Flexible materials from which the mesh substrate can be made include cloth (e.g., cloth made from fibers or yams comprising polyester, nylon, silk, cotton, and / or rayon, which may be woven, knit or stitch bonded) and scrim. The mesh substrate optionally comprises a loop backing.

[0103] Exemplary suitable polymeric materials for use as the discontinuous polymeric layer include for instance and without limitation, a phenolic polymer, a urea-formaldehyde polymer, a (methjacrylic polymer, an epoxy polymer, an epoxy acrylate polymer, or combinations thereof. In some cases, the polymeric material may be provided as a layer of hot melt polymer subjected to heating to liquify the polymer for coating on the mesh substrate or on the solid substrate.

[0104] In select embodiments, the discontinuous polymeric layer includes at least one mineral distributed in a polymeric matrix. Exemplary suitable minerals (e.g., the second abrasive particles) include for instance and without limitation, fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, and combinations thereof. In certain cases, the minerals include fused aluminum oxide, ceramic aluminum oxide, heat treated aluminum oxide, white aluminum oxide, green silicon carbide, silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, and combinations thereof

[0105] Abrasive particles for attachment to the multilayer substrate are not limited and may be composed of any of a wide variety of hard minerals known in the art. Examples of suitable abrasive particles include, for instance and without limitation, fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boronnitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof. The alumina abrasive particles may contain a metal oxide modifier. The diamond and cubic boron nitride abrasive particles may be monocrystalline or polycrystalline.

[0106] As noted above, fine grade abrasive particles may have a smaller particle size than the height of the surface roughness of a mesh substrate. For instance, particles of 400 grade in size have a D50 (i.e., a median diameter) of 45 micrometers. Particles of 800 grade in size have a D50 of 21 micrometers. A Coulter Counter may be used to determine the volume distribution particle size. FEPA Grains Standard, the Worlwide Reference for Abrasives. For abrasives, particle size is carefully controlled in accordance with FEPA’s own developed European standards. Grit sizes, measures and appellation differ depending on abrasive products: Bonded abrasives: F-grit sizes; Coated abrasives: P-grit sizes; Superabrasives: The grit designation is prefixed with a “D” to denote Diamond and a “B” to denote cBN. It is noted that F- grits conform to FEPA Standard 42-1:2006 and P-grits conform to FEPA Standards 43-1:2006 and 43- 2:2006. FEPA Standards define the mean diameters of macrogrits as a range and not a single value. The particle size distribution of macrogrits is determined by sieving, while the microgrits have been measured by sedimentation (photosedimentometer). For grit sizes between F4 and F220, the micron size is based upon the 40% minimum sieve. For grit sizes between F230 and F2000, the micron size is based upon the average of the D50. For instance, F230: 53 microns, F:240: 44.5 microns, F280: 36.5 microns, F320: 29.2 microns, F360 :22.8 microns, F400: 17.3 microns, F500: 12.8 microns, F600: 9.3 microns, F800: 6.5 microns, F1000: 4.5 microns, F1200: 3 microns, F1500: 2 microns, F2000: 1.2 microns. The particle size of the (e.g., second) abrasive particles that are distributed in the discontinuous polymeric layer is 36 to 8000 grade in size. The size is not particularly limited within the range, and may be 36 grade or higher, 40, 50, 75, 100, 150, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1200, 1400, 1600, 1800, 2000, 2200, 2400, 2600, 2800, 3000, 4000, or 5000 grade or higher; and 30000 grade or lower, 25000, 20000, 15000, 12000, 10000, 9000, 8000, 7000, 6000, 5000, 4000, 3000, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, or 1000 grade or lower. The particle size of the (e.g., first) abrasive particles that are attached to a discontinuous polymeric layer (either directly (e.g., electrostatically) or using a binder) is 36 to 30000 grade in size. The size is not particularly limited within the range, and may be 36 grade or higher, 40, 50, 75, 100, 150, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 grade or higher; and 30000 grade or lower, 25000, 20000, 15000, 12000, 10000, 9000, 8000, 7000, 6000, 5000, 4000, 3000, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, or 1000 grade or lower. In some cases, the plurality of first abrasive particles is of 180 to 2000 grade in size or 600 to 2000 grade in size. Optionally, a blend of two or more mineral types and / or grades can be used together.

[0107] In the case of articles having a planar surface, the polymeric layer creates a smooth top surface. This semi-plateau like feature created by the polymeric layer has a clearly defined edge and steep drop off where the plane is discontinued. When measuring the potential abrasive bearing area, the area containing abrasive particles able to engage a substrate, the resulting polymeric layer imparted surface area does not change. Generally, as the relative size of abrasive particle decreases with grade range, the bearing area ona 3-dimensional curved surface, such as a mesh, is also changing with respect to the particle size. However, there is very little change in potential bearing area by grade size for the articles having a planar surface due to the steepness of the polymeric layer plateau. The smooth top surface allows for a high bearing area of many particle sizes, however, the steep drop off of the feature of the polymeric layer plateau does not allow for much expansion of the bearing area with respect to particle size increase. In this way, the bearing area is not changing from grade to grade for the abrasive particles on the planarized mesh substate.

[0108] Abrasive particles used in embodiments herein, whether crushed or shaped, should have sufficient hardness and surface roughness to function as abrasive particles in an abrading 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.

[0109] Useful abrasive materials include, for example, fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, ceramic aluminum oxide materials such as those commercially available as 3M CERAMIC ABRASIVE GRAIN from 3M Company of St. Paul, Minnesota, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, tungsten carbide, titanium carbide, cubic boron nitride, garnet, fused alumina zirconia, sol-gel derived ceramics (e.g., alumina ceramics doped with chromia, ceria, zirconia, titania, silica, and / or tin oxide), silica (e.g., quartz, glass beads, glass bubbles and glass fibers), feldspar, or flint. Examples of sol-gel derived crushed ceramic particles can be found in U.S. Pat. Nos. 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.).

[0110] As noted above, the abrasive particles may be shaped (e.g., precisely -shaped) or random (e.g., crushed). Shaped abrasive particles and precisely-shaped abrasive particles can be prepared, for example, by a molding process using sol-gel technology as described in U.S. Pat. Nos. 5,201,916 (Berg); 5,366,523 (Rowenhorst (Re 35,570)); and 5,984,988 (Berg). U.S. Pat. No. 8,034,137 (Erickson et al.) describes alumina particles that have been formed in a specific shape, then crushed to form shards that retain a portion of their original shape features. Exemplary shapes of abrasive particles include crushed, pyramids (e.g., 3-, 4-, 5-, or 6-sided pyramids), truncated pyramids (e.g., 3-, 4-, 5-, or 6-sided truncated pyramids), cones, truncated cones, rods (e.g., cylindrical, vermiform), and prisms (e.g., 3-, 4-, 5-, or 6- sided prisms).

[0111] The abrasive particles may be independently sized according to an abrasives industry recognized specified nominal grade. Exemplary abrasive industry recognized grading standards include those promulgated by ANSI (American National Standards Institute), FEPA (Federation of European Producers of Abrasives), and JIS (Japanese Industrial Standard). ANSI grade designations (i.e., specified nominal grades) include, for example: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 46, ANSI 54, ANSI 60, ANSI 70, ANSI 80, ANSI 90, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600. FEPA grade designations include F4, F5, F6, F7, F8, F10, F12, F14, F16, F20, F22, F24, F30, F36, F40, F46, F54, F60, F70, F80, F90, F100, F120, F150, F180, F220, F230, F240, F280, F320, F360, F400, F500, F600, F800, F1000,F1200, F1500, F2000, P12, P16, P20, P24, P30, P36, P40, P50, P60, P80, P100, P120, P15O, P180, P220, P240, P280, P320, P360, P400, P5OO, P600, P800, P1OOO, P1200, P15OO, P2000, and P2500. JIS grade designations include JIS8, JIS 12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS1OO, JIS15O, JIS18O, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1OOO, JIS15OO, JIS2500, JIS4000, JIS6000, JIS8000, and JIS 10,000.

[0112] Examples of shaped abrasive particles can be found in U.S. Pat. Nos. 5,201,916 (Berg); 5,366,523 (Rowenhorst (Re 35,570)); and 5,984,988 (Berg). U.S. Pat. No. 8,034,137 (Erickson et al.) describes alumina crushed abrasive particles that have been formed in a specific shape, then crushed to form shards that retain a portion of their original shape features. In some embodiments, shaped alpha alumina particles are precisely-shaped (i.e., the particles have shapes that are at least partially determined by the shapes of cavities in a production tool used to make them. Details concerning such precisely- shaped abrasive particles and methods for their preparation can be found, for example, in U. S. Pat. Nos. 8,142,531 (Adefris et al.); 8,142,891 (Culler et al.); and 8,142,532 (Erickson et al.); and in U.S. Pat. Appl. Publ. Nos. 2012 / 0227333 (Adefris et al.); 2013 / 0040537 (Schwabel et al.); and 2013 / 0125477 (Adefris).

[0113] In embodiments wherein the abrasive particles are shaped as triangular platelets (or triangular frustopyramids), they may have a major surface with a vertex of 90 degrees (corresponding to a right triangle), or they may have a major surface with a vertex of greater than 90 degrees (corresponding to an obtuse triangle), although this is not a requirement. Examples include at least 91 degrees, at least 95 degrees, at least 100 degrees, at least 110 degrees, at least 120 degrees, or even at least 130 degrees.

[0114] In some preferred embodiments, the abrasive particles comprise platey crushed abrasive particles. Such abrasive particles can be obtained by known methods, from commercial suppliers, and / or by shape sorting such crushed abrasive particles; for example, using a shape-sorting table as is known in the art.

[0115] Examples of suitable abrasive particles include cmshed abrasive particles comprising fused aluminum oxide, heat-treated aluminum oxide, white fused aluminum oxide, ceramic aluminum oxide materials such as those commercially available as 3M CERAMIC ABRASIVE GRAIN from 3M Company, St. Paul, Minnesota, brown aluminum oxide, blue aluminum oxide, silicon carbide (including green silicon carbide), titanium diboride, boron carbide, tungsten carbide, garnet, titanium carbide, diamond, cubic boron nitride, fused alumina zirconia, iron oxide, chromia, zirconia, titania, quartz, feldspar, flint, emery, sol-gel-derived ceramic (e.g., alpha alumina), and combinations thereof. Further examples include crushed abrasive composites of abrasive particles (which may be platey or not) in a binder matrix, such as those described in U.S. Pat. No. 5,152,917 (Pieper et al.). Many such abrasive particles, agglomerates, and composites are known in the art.

[0116] Preferably, crushed abrasive particles comprise ceramic crushed abrasive particles such as, for example, sol-gel-derived polycrystalline alpha alumina particles. Ceramic crushed abrasive particles composed of crystallites of alpha alumina, magnesium alumina spinel, and a rare earth hexagonal aluminate may be prepared using sol-gel precursor alpha alumina particles according to methods described in, for example, U.S. Pat. No. 5,213,591 (Celikkaya et al.) and U.S. Publ. Pat. Appln. Nos. 2009 / 0165394 Al (Culler et al.) and 2009 / 0169816 Al (Erickson et al.).

[0117] Examples of sol-gel-derived abrasive particles from which crushed abrasive particles can be isolated, and methods for their preparation can be found, in U.S. Pat. Nos. 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 cmshed abrasive particles could comprise abrasive agglomerates such, for example, as those described in U.S. Pat. Nos. 4,652,275 (Bloecher et al.) or 4,799,939 (Bloecher et al.). In some embodiments, the crushed abrasive particles may be surface-treated with a coupling agent (e.g., an organosilane coupling agent) or other physical treatment (e.g., iron oxide or titanium oxide) to enhance adhesion of the cmshed abrasive particles to a binder. The crushed abrasive particles may be treated before combining them with the binder, or they may be surface treated in situ by including a coupling agent to the binder.

[0118] Further details concerning methods of making sol-gel-derived abrasive particles can be found in, for example, U.S. Pat. Nos. 4,314,827 (Leitheiser); 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.); and in U.S. Publ. Pat. Appln. No. 2009 / 0165394 Al (Culler et al.).

[0119] Surface coatings on the various abrasive particles may be used to improve the adhesion between the abrasive particles and a binder in abrasive articles, or can be used to aid in electrostatic deposition. In one embodiment, surface coatings as described in U.S. Pat. No. 5,352,254 (Celikkaya) in an amount of 0.1 to 2 percent surface coating to abrasive particle weight may be used. Such surface coatings are described in U.S. Pat. Nos. 5,213,591 (Celikkaya 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 may prevent the shaped abrasive particle from capping. Capping is the term to describe the phenomenon where metal particles from the workpiece being abraded become welded to the tops of the crushed abrasive particles. Surface coatings to perform the above functions are known to those of skill in the art.

[0120] Crushed abrasive particles used in practice of the present disclosure are preferably selected to have a length and / or width in a range of from 0.1 micron to 3500 microns, more typically 100 microns to 3000 microns, and more typically 100 microns to 2600 microns, although other lengths and widths may also be used.

[0121] Crushed abrasive particles may be selected to have a thickness in a range of from 0.1 micron to 1600 microns, more typically from 1 micron to 1200 microns, although other thicknesses may be used. In some embodiments, platey crushed abrasive particles may have an aspect ratio (length to thickness) of at least 2, 3, 4, 5, 6, or more.

[0122] Length, width, and thickness of the abrasive particles can be determined on an individual or average basis, as desired. Suitable techniques may include inspection and measurement of individual particles, as well as using automated image analysis techniques (e.g., using a dynamic image analyzer such as a CAMSIZER XT image analyzer from Retsch Technology Gmbh of Haan, Germany) according to test method ISO 13402-2:2006 "Particle size analysis - Image analysis methods - Part 2: Dynamic image analysis methods".

[0123] Any of a wide selection of make and size resins known in the art may be used to secure the abrasive particles to the discontinuous polymeric layer. The resins typically include one or more binders having rheological and wetting properties suitable for selective deposition onto a backing. Typically, binders are formed by curing (e.g., by thermal means, or by using electromagnetic or particulate radiation) a binder precursor. Useful first and second binder precursors are known in the abrasive art and include, for example, free-radically polymerizable monomer and / or oligomer, epoxy resins, acrylic resins, epoxy-acrylate oligomers, urethane-acrylate oligomers, urethane resins, phenolic resins, ureaformaldehyde resins, melamine-formaldehyde resins, aminoplast resins, cyanate resins, or combinations thereof. Useful binder precursors include thermally curable resins and radiation curable resins, which may be cured, for example, thermally and / or by exposure to radiation. Exemplary radiation cured binders are described in U.S. Patent Nos. 4,751,138 (Tumey, et al.) and 4,828,583 (Oxman, et al.).

[0124] In a third aspect, a method of making a multilayer substrate is provided. The method comprises:

[0125] applying a liquid polymeric composition on a first major surface of a mesh substrate;

[0126] pressing a solid substrate against the coated mesh substrate; and

[0127] curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate, wherein either:

[0128] a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or

[0129] b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

[0130] FIG. 6 is a flow chart of an exemplary method of making a multilayer substrate, according to embodiments of the present disclosure. The method comprises the operations to: Coat a liquid polymeric composition on a first major surface of a mesh substrate 6010; Press a solid substrate against the coated mesh substrate 6020; and Cure the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate, wherein either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer 6030.

[0131] Referring now to FIGS. 7A-C, a general schematic cross-sectional depiction is provided of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure. In FIG. 7A, a mesh substrate 7100 is shown as having two general portions: a surface roughness 7150 and base mesh 7160. The surface roughness 7150 includes mesh material that protmdes 7152 above a two-dimensional plane defined by an upper surface 7162 of the base mesh 7160, and one gap 7230 can be seen between adjacent protrusions of mesh material 7152. An opposing major surface7120 of the mesh substrate 7100 is also visible in FIGS. 7A-7C. First, as shown in FIG. 7B, a liquid polymeric composition 7400 is coated on a first major surface 7110 of the mesh substrate 7100; in this case, the liquid polymeric composition 7400 is coated on the surface roughness 7150 portion of the mesh substrate 7100 without substantially extending down to the base mesh 7160, which assists in maintaining a porosity of the mesh substrate 7100. The liquid polymeric composition 7400 is coated discontinuously across the first major surface 7110 of the mesh substrate 7100. Optionally, the liquid polymeric composition 7400 comprises at least one mineral distributed in a polymeric matrix. FIG. 7C shows different options for performing additional operations. In each, a solid substrate 7800 is pressed against the coated mesh substrate 7020 and then the liquid polymeric composition 7400 is cured to form portions of polymeric material 7205. In one option, curing is performed using actinic radiation (e.g., ultraviolet radiation) 7900 to polymerize a polymerizable liquid polymeric composition 7400. In the other option, the solid substrate 7800 is either heated or cooled 7850 to assist in curing by drying or solidifying the liquid polymeric composition 7400. It is also expressly contemplated that both of these curing methods may be employed with the same multilayer substrate. As such, in some embodiments, the liquid polymeric composition is cured using at least one of actinic radiation or drying. Additionally, it is understood that the curing operation can be performed from either side of the mesh substrate or from both sides. The gap 7230 is maintained in the final multilayer substrate 7000. As indicated by the curve and upward arrow on the solid substrate 7800, often the method further includes removing the solid substrate 7800.

[0132] Referring now to FIGS. 8A-D, a general schematic cross-sectional depiction is provided of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure. In FIG. 8A, a mesh substrate 8100 is shown as having two general portions: a surface roughness 8150 and base mesh 8160. The surface roughness 8150 includes mesh material that protmdes 8152 above a two-dimensional plane defined by an upper surface 8162 of the base mesh 8160, and one gap 8230 can be seen between adjacent protrusions of mesh material 8152. An opposing major surface 8120 of the mesh substrate 8100 is also visible in FIGS. 8A-8D. First, as shown in FIG. 8B, a liquid polymeric composition 8400 is coated on a first major surface 8110 of the mesh substrate 8100; in this case, the liquid polymeric composition 8400 is coated on the surface roughness 8150 portion of the mesh substrate 8100 without substantially extending down to the base mesh 8160, which assists in maintaining a porosity of the mesh substrate 8100. The liquid polymeric composition 8400 is coated discontinuously across the first major surface 8110 of the mesh substrate 8100. Optionally, the liquid polymeric composition 8400 comprises at least one mineral distributed in a polymeric matrix. FIG. 8C shows different options for performing additional operations. In each, a solid substrate 8800 having a structured surface 8855 is pressed against the coated mesh substrate 8020 and then the liquid polymeric composition 8400 is cured to form portions of polymeric material 8205. In one option, curing is performed using actinic radiation (e.g., ultraviolet radiation) 8900 to polymerize a polymerizable liquid polymeric composition 8400. In the other option, the solid substrate 8800 is either heated or cooled 8850 to assist in curing by drying or solidifying the liquid polymeric composition 8400. Additionally, it is understood thatthe curing operation can be performed from either side of the mesh substrate or from both sides. This method further comprises the operation of removing the solid substrate 8800, which, as shown in FIG. 8D, results in a complementary structured surface 8255 formed in the discontinuous polymeric layer 8200 disposed on an exterior 8112 of the first major surface 8110 of the mesh substrate 8100. The gap 8230 is maintained in the final multilayer substrate 8000.

[0133] As depicted in each of FIGS. 4B, 4C, 7B, 7C, 8B, 8C, and 8D, in some embodiments of a multilayer substrate, the mesh substrate comprises a surface roughness and a base mesh and the discontinuous polymeric layer is present in and / or on the surface roughness without substantially extending down to the base mesh, which assists in maintaining a porosity of the mesh substrate. It is noted that the surface roughness is a part of the first major surface of the mesh substrate, and may have an average thickness of 50 micrometers or greater (e.g., up to about 1 millimeters).

[0134] In a fourth aspect, another method of making a multilayer substrate is provided. The method comprises:

[0135] applying a liquid polymeric composition on a first major surface of a solid substrate;

[0136] pressing a mesh substrate against the coated solid substrate; and

[0137] curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate,

[0138] wherein either:

[0139] a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or

[0140] b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

[0141] FIG. 9 is a flow chart of a further exemplary method of making a multilayer substrate, according to embodiments of the present disclosure. The method comprises the operations to: Apply a liquid polymeric composition on a first major surface of a solid substrate 9010; Press a mesh substrate against the coated solid substrate 9020; and Cure the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate and wherein either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer 9030.

[0142] Referring to FIGS. 10A-10D, a general schematic cross-sectional depiction is provided of another exemplary method of making a multilayer substrate, according to embodiments of the present disclosure. In FIG. 10A, a solid substrate 10800 is shown having a liquid polymeric composition 10400 applied to a first major surface 10810 thereof, providing a coated substrate 10805. It is noted that the solid substrate10800 may be a surface of a roll. Optionally, the liquid polymeric composition 10400 comprises at least one mineral distributed in a polymeric matrix. As can be seen in the figure, the liquid polymeric composition 10400 is a discontinuous coating with a gap 10430 between adjacent portions of liquid polymeric composition 10400. In FIG. 10B, a mesh substrate 10100 has been pressed against the coated substrate 10805. The mesh substrate 10100 is shown as having two general portions: a surface roughness 10150 and base mesh 10160. The surface roughness 10150 includes mesh material that protrudes 10152 beyond a two-dimensional plane defined by an upper surface 10162 of the base mesh 10160, and three gaps 10230 can be seen between adjacent protrusions of mesh material 10152. An opposing major surface 10120 of the mesh substrate 10100 is also visible in FIGS. 10B-10D. The mesh substrate 10100 is pressed against the coated substrate 10805 such that the protrusions of mesh material 10152 project into the liquid polymeric composition 10400 approximately until the upper surface 10162 of the base mesh 10160 reaches the liquid polymeric composition 10400, while retaining the gap 10430 between adjacent portions of liquid polymeric composition 10400. As depicted in FIG. 10B, the gap 10430 between adjacent portions of liquid polymeric composition 10400 matches up with one of the three gaps 10230 between adjacent protrusions of mesh material 10152; it is not necessary to have alignment to a gap 10430 for every gap 10230. Optionally, the polymeric layer pattern and area coverage can be partially or entirely independent from the mesh primary fibers and is controlled by the coating or patterning method utilized to deposit the discontinuous polymeric layer.

[0143] FIG. 10C shows different options for performing additional operations. In each, the liquid polymeric composition 10400 is cured (to form portions of polymeric material 10205, which are not shown in FIG. 10C). In one option, curing is performed using actinic radiation (e.g., ultraviolet radiation) 10900 to polymerize the polymerizable liquid polymeric composition 10400. In the other option, the mesh substrate 10100 is either heated or cooled 10150 to assist in curing by drying or solidifying the liquid polymeric composition 10400. It is also expressly contemplated that both of these curing methods may be employed with the same multilayer substrate. As such, in some embodiments, the liquid polymeric composition is cured using at least one of actinic radiation or drying. Further, it is additionally expressly contemplated that curing may be performed as depicted directing actinic radiation or heat (e.g., thermal curing) at the polymerizable liquid polymeric composition 10400 from above but could also or alternatively be directed at the polymerizable liquid polymeric composition 10400 from the opposite side of the solid substrate 10800. Referring to FIG. 10D, the solid substrate (10800) has been removed, leaving the final multilayer substrate 10000 that has a planar discontinuous polymeric layer 10200 disposed on an exterior 10112 of the first major surface 10110 of the mesh substrate 10100. It is noted that the gap 10430 is maintained in the final multilayer substrate 10000.

[0144] Referring now to FIGS. 11A-11D, a general schematic cross-sectional depiction is provided of a further exemplary method of making a multilayer substrate, according to embodiments of the present disclosure. In FIG. 11 A, a solid substrate 11800 is shown, which has a structured surface 11855. The solid substrate 11800 has a liquid polymeric composition 11400 applied to the structured surface 11855, providing a coated substrate 11805. It is noted that the solid substrate 11800 may be a surface of animpression roll. Optionally, the liquid polymeric composition 11400 comprises at least one mineral distributed in a polymeric matrix. As can be seen in the figure, the liquid polymeric composition 11400 is a discontinuous coating with a gap 11430 between adjacent portions of liquid polymeric composition 11400. In FIG. 1 IB, a mesh substrate 11100 has been pressed against the coated substrate 11805. The mesh substrate 11100 is shown as having two general portions: a surface roughness 11150 and base mesh 11160. The surface roughness 11150 includes mesh material that protrudes 11152 beyond a two- dimensional plane defined by an upper surface 11162 of the base mesh 11160, and three gaps 11230 can be seen between adjacent protrusions of mesh material 11152. An opposing major surface 11120 of the mesh substrate 11100 is also visible in FIGS. 1 IB-1 ID. The mesh substrate 11100 is pressed against the coated substrate 11805 such that the protrusions of mesh material 11152 project into the liquid polymeric composition 11400 approximately until the upper surface 11162 of the base mesh 11160 reaches the liquid polymeric composition 11400, while retaining the gap 11430 between adjacent portions of liquid polymeric composition 11400. As depicted in FIG. 1 IB, the gap 11430 between adjacent portions of liquid polymeric composition 11400 matches up with one of the three gaps 11230 between adjacent protrusions of mesh material 11152; it is not necessary to have alignment to a gap 11430 for every gap 11230.

[0145] FIG. 11C shows different options for performing additional operations. In each, the liquid polymeric composition 11400 is cured to form portions of polymeric material 11205. In one option, curing is performed using actinic radiation (e.g., ultraviolet radiation) 11900 to polymerize the polymerizable liquid polymeric composition 11400. In the other option, the mesh substrate 11100 is either heated or cooled 11150 to assist in curing by drying or solidifying the liquid polymeric composition 11400. It is also expressly contemplated that both of these curing methods may be employed with the same multilayer substrate. As such, in some embodiments, the liquid polymeric composition is cured using at least one of actinic radiation or drying. Further, it is additionally expressly contemplated that curing may be performed as depicted directing actinic radiation or heat (e.g., thermal curing) at the polymerizable liquid polymeric composition 11400 from above but could also or alternatively be directed at the polymerizable liquid polymeric composition 11400 from the opposite side of the solid substrate 11800. Additionally, it is understood that the curing operation can be performed from either side of the mesh substrate or from both sides. Referring to FIG. 1 ID, the solid substrate 11800 has been removed to provide the final multilayer substrate 11000. The removal of the structured solid substrate 11800 results in a complementary structured surface 11255 formed in the discontinuous polymeric layer 11200 disposed on an exterior 11112 of the first major surface 11110 of the mesh substrate 11100. It is noted that the gap 11430 is maintained in the final multilayer substrate 11000.

[0146] In any embodiment, application of the liquid polymeric composition can vary. In some embodiments, the liquid polymeric composition is applied on a portion of (e.g., the first major surface) of a solid substrate, for transfer to a mesh substrate. Alternatively, the liquid polymeric composition may be applied on the entirety of (e.g., the first major surface) of a solid substrate, for transfer to a mesh substrate. Placing the liquid polymeric composition on a solid substrate instead of the mesh substratemay be advantageous due to the regular surface (either planar or structured) of the solid substrate, which is not as variable as the exterior (e.g., fibrous) surface of a mesh substrate. Often, an area coverage of the application of the liquid polymeric composition on the solid substrate is controlled. In some cases, the liquid polymeric composition is applied in a pattern. The pattern may be continuous or discontinuous. Any suitable application methods of creating patterns may be employed, for example: flexographic printing, gravure printing, screen printing, stencil printing, rotary screen printing, rotary stencil printing, inkjet printing, stripe coating, patch coating, dispensing, and the like. In some embodiments, the liquid polymeric composition is applied on at least a portion of (e.g., the first major surface) of a mesh substrate. In some cases, the pattern is influenced by the substrate structure, but in others not.

[0147] Exemplary suitable solid substrates preferably exhibit release characteristics and / or a low surface energy, to minimize adherence of the polymeric material to the solid substrate following manufacture of a multilayer substrate. A release surface can be provided by any suitable material (or, by any suitable treatment of the surface of the material of which a release liner is made). Such a release surface might be e.g., any suitable coating, for example wax or the like. Or, any suitable high molecular weight polymeric layer (e.g., coating) might be used, e.g., a polyolefin layer such as polyethylene, and so on. It will be appreciated that numerous layers and treatments can be suitable for such use. The solid substrate can be of a variety of forms including, e.g., sheet, tape, roll, sleeve, and film. Examples of suitable materials include, e.g., paper (e.g., kraft paper, poly-coated paper and the like), low surface energy polymer films (e.g., polyethylene, polypropylene, and polyester), silicone sheets or silicone coated surfaces (films, paper, wovens, nonwovens, rolls, idlers, sleeves), composite liners, and combinations thereof.

[0148] In select embodiments, suitable solid substrates have a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less. In alternate embodiments, suitable solid substrates have a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

[0149] In some cases, the liquid polymeric composition is coated on a mesh substrate using a roll-to-roll coating process. FIG. 12 is a general schematic side view depiction of a roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure. One suitable roll-to-roll method of preparing a multilayer substrate 12000 includes using a metered application of the liquid polymeric composition 12400 on a first major surface 12110 of the mesh substrate 12100. Such a method involves using a metering roll 12300 to apply the liquid polymeric composition 12400 onto a coating roll 12310, then passing a mesh substrate 12100 in between an impression roll 12320 and the coating roll 12310. Accordingly, the liquid polymeric composition 12400 is pressed on the mesh substrate 12100 in between the coating roll 12310 and the impression roll 12320. In some cases, a suitable coating roll has a Shore A durometer of 30 or greater, 35, 40, 45, 50, or 55 or greater; and 70 or less, 65, 60, 55, or 50 or less. In this particular method, the combination of mesh substrate 12100 and liquid polymeric composition 12400 are passed around a curing roll 12330 and subjected to curing 12900 by actinicradiation and / or drying, resulting in a discontinuous polymeric layer 12200 on a first major surface 12110 of the mesh substrate 12100.

[0150] FIG. 13 is a general schematic side view depiction of another roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure. This roll-to-roll method of preparing a multilayer substrate 13000 includes an application of the liquid polymeric composition 13400 through a rotary screen 13340 on a release roll 13350. A mesh substrate 13100 is passed in between an impression roll 13320 and the release roll 13350. Accordingly, the liquid polymeric composition 13400 is pressed on a first major surface 13110 of the mesh substrate 13100 in between the release roll 13350 and the impression roll 13320. In this particular method, the combination of mesh substrate 13100 and liquid polymeric composition 13400 are subjected to curing 13900 by actinic radiation and / or drying, resulting in a discontinuous polymeric layer 13200 on a first major surface 13110 of the mesh substrate 13100.

[0151] FIG. 14 is a general schematic side view depiction of an additional roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure. This roll-to-roll method of preparing a multilayer substrate 14000 includes an application of the liquid polymeric composition 14400 through a rotary screen 14340 on a release belt 14360 as it passes around an impression roll 14320. The release belt optionally also passes around one or more rolls 14370, e.g., tension / idle / impression rolls. A mesh substrate 14100 is passed inbetween at least one roll 14370 and the release belt 14360. Accordingly, the liquid polymeric composition 14400 is pressed on a first major surface 14110 of the mesh substrate 14100 inbetween the release belt 14360 and at least one roll 14370. In this particular method, the combination of mesh substrate 14100 and liquid polymeric composition 14400 are subjected to curing 14900 by actinic radiation and / or drying, resulting in a discontinuous polymeric layer 14200 on a first major surface 14110 of the mesh substrate 14100.

[0152] FIG. 15 is a general schematic side view depiction of a further roll-to-roll method of making a multilayer substrate, according to embodiments of the present disclosure. This roll-to-roll method of preparing a multilayer substrate 15000 includes an application of a hot melt polymeric material by heating a solid polymeric material to form a liquid polymeric composition 15400 that is then applied through a heated rotary screen 15340 on a release belt 15360 as it passes around an impression roll 15320. The release belt optionally also passes around one or more rolls 15370, e.g., tension / idle / impression rolls. A mesh substrate 15100 is passed inbetween at least one roll 15370 and the release belt 15360. Accordingly, the liquid polymeric composition 15400 is pressed on a first major surface 15110 of the mesh substrate 15100 in between the release belt 15360 and at least one roll 15370. In this particular method, the combination of mesh substrate 15100 and liquid polymeric composition 15400 are subjected to curing by cooling, resulting in a discontinuous polymeric layer 15200 on a first major surface 15110 of the mesh substrate 15100.

[0153] One specific advantage of roll-to-roll methods according to at least certain embodiments of the present disclosure is that due to the ability to provide a continuous pattern on a roll, the resulting article (e.g., multilayer substrate or abrasive article) can exhibit a seamless pattern of the discontinuouspolymeric layer. A seamless pattern enables the option of removing (e.g., cutting) individual pieces from a larger article with no concern of trying to avoid a seam present on the article, giving greater freedom to selecting which portion(s) of a large article to remove. This is in contrast to laminating a pattern onto a article in which the pattern is smaller than the surface area of the article, which will result in at least one seam between portions of the pattern.

[0154] In certain embodiments, a viscosity of the liquid polymer composition is important to achieve a desired application amount on a mesh substrate. In select cases, the liquid polymeric composition displays a Newtonian behavior or a shear thinning behavior. In select cases, the liquid polymeric composition displays a shear viscosity between 50 Pascal seconds (Pa*s) and 2000 Pa*s at a shear rate of 0.1 s'1at 23°C or a shear viscosity between 0.5 Pa*s and 20 Pa*s at a shear rate of 1000 s'1at 23°C. In select cases, the liquid polymeric composition displays a shear viscosity between 100 Pascal seconds (Pa*s) and 10000 Pa*s at a shear rate of 0.1 s'1at 23 °C or a shear viscosity between 1 Pa*s and 10 Pa*s at a shear rate of 1000 s'1at 23°C. In select cases, the liquid polymeric composition displays a shear viscosity between 1 Pascal seconds (Pa*s) and 100 Pa*s at a shear rate of 0.1 s'1at 23°C or a shear viscosity between 1 Pa*s and 100 Pa*s at a shear rate of 1000 s'1at 23°C. In select cases, the liquid polymeric material can require heating to achieve the desired shear viscosity. In select cases, the liquid polymeric composition displays a shear viscosity between 5 Pa*s and 100 Pa*s at a shear rate of 1 s'1at 38°C or a shear viscosity between 5 to 100 Pa*s at a shear rate of 500 s'1at 38°C. In another embodiment, the liquid polymeric composition displays a shear viscosity between 100 Pa*s and 1000 Pa*s at a shear rate of 1 s'1at 120°C or a shear viscosity between 0.1 to 10 Pa*s at a shear rate of 1000 s'1at 120°C.

[0155] In a fifth aspect, a method of making an abrasive article is provided. The method comprises obtaining a multilayer substrate according to any embodiment of the first aspect described in detail above; and attaching a plurality of first abrasive particles of 36 to 30000 grade in size to the designed surface.

[0156] Referring now to FIG. 16, a flow chart is provided of an exemplary method of making an abrasive article, according to embodiments of the present disclosure. The method comprises the operations to: Obtain a multilayer substrate according to the first aspect 16010; and Attach a plurality of first abrasive particles of 36 to 30000 grade in size to the designed surface 16020. In some cases, attaching the first abrasive particles includes applying a binder to the multilayer substrate; and at least partially embedding the first abrasive particles in the binder. Optionally, a blend of two or more mineral types and / or grades can be used together. Also optionally, the method may further include applying a size coat to the first abrasive particles. Attaching abrasive particles to substrates is well known in the art; for instance, abrasive particles may be attached to substrates according to methods described in detail in U.S. Patent Nos. 10,688,625 (Meuler et al.) or 9,630,297 (Janssen et al.), incorporated by reference herein in their entireties. Additionally, in some embodiments in which a size coat is present, a supersize coat may be present over the size coat.

[0157] In a sixth aspect, another method of making an abrasive article is provided. The method comprises making a multilayer substrate having at least one mineral distributed in the discontinuouspolymeric material and using a solid substrate that has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer. The mineral comprises a plurality of second abrasive particles of 36 to 30000 grade in size and comprising fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof. As such, the combination of abrasive particles present within the discontinuous polymer material and the patterned structured major surface of the discontinuous polymer material can act as an abrading surface of the abrasive article.

[0158] In a seventh aspect, another method of making an abrasive article is provided. The method comprises applying a liquid polymeric composition on a first major surface of a mesh substrate, the liquid polymeric composition comprising at least one mineral distributed therein. The method further comprises pressing a solid substrate against the coated mesh substrate, wherein the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer. Additionally, the method comprises curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate.

[0159] Listing of Exemplary Embodiments

[0160] In a first embodiment, the present disclosure provides a multilayer substrate. The multilayer substrate comprises a mesh substrate having a first major surface and an opposing major surface; and a discontinuous polymeric layer disposed on an exterior of the first major surface. The discontinuous polymeric layer provides a designed surface of the multilayer substrate. The discontinuous polymeric layer has a first major surface that is opposite the mesh substrate, and either: a) the first major surface of the discontinuous polymeric layer comprises a planar surface, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the first major surface of the discontinuous polymeric layer comprises a patterned structured surface.

[0161] In a second embodiment, the present disclosure provides a multilayer substrate according to the first embodiment, wherein the mesh substrate is in a form of a net comprising a plurality of each of primary fibers, secondary fibers, and tertiary fibers.

[0162] In a third embodiment, the present disclosure provides a multilayer substrate according to the second embodiment, comprising a plurality of gaps between adjacent portions of the discontinuous polymeric layer located between adjacent primary fibers.

[0163] In a fourth embodiment, the present disclosure provides a multilayer substrate according to any of the first through third embodiments, wherein the discontinuous polymeric layer comprises a phenolicpolymer, a urea-formaldehyde polymer, a (meth)acrylic polymer, an epoxy polymer, an epoxy acrylate polymer, or combinations thereof.

[0164] In a fifth embodiment, the present disclosure provides a multilayer substrate according to any of the first through fourth embodiments, wherein the discontinuous polymeric layer comprises at least one mineral distributed in a polymeric matrix.

[0165] In a sixth embodiment, the present disclosure provides a multilayer substrate according to any of the first through fifth embodiments, wherein the mesh substrate comprises a woven fabric or a knitted fabric.

[0166] In a seventh embodiment, the present disclosure provides a multilayer substrate according to any of the first through sixth embodiments, exhibiting a surface area of 20% or greater than the mesh substrate alone.

[0167] In an eighth embodiment, the present disclosure provides a multilayer substrate according to any of the first through seventh embodiments, exhibiting a Young's modulus that is at least 50% larger than the mesh substrate alone.

[0168] In a ninth embodiment, the present disclosure provides a multilayer substrate according to any of the first through eighth embodiments, wherein the first major surface of the discontinuous polymeric layer comprises a planar surface, wherein the designed surface exhibits an average flatness of 50 micrometers or less.

[0169] In a tenth embodiment, the present disclosure provides a multilayer substrate according to any of the first through eighth embodiments, wherein the first major surface of the discontinuous polymeric layer comprises a patterned structured surface.

[0170] In an eleventh embodiment, the present disclosure provides an abrasive article. The abrasive article comprises a multilayer substrate according to any of the first through tenth embodiments; and at least one of: i) a plurality of first abrasive particles of 36 to 30000 grade in size attached to the designed surface; or ii) a plurality of second abrasive particles of 36 to 30000 grade in size distributed in the discontinuous polymeric layer.

[0171] In a twelfth embodiment, the present disclosure provides an abrasive article according to the eleventh embodiment, wherein the plurality of first abrasive particles is present and of 600 to 2000 grade in size.

[0172] In a thirteenth embodiment, the present disclosure provides an abrasive article according to the eleventh or twelfth embodiment, further comprising a binder disposed on the designed surface, wherein the plurality of first abrasive particles is present and at least partially embedded in the binder.

[0173] In a fourteenth embodiment, the present disclosure provides an abrasive article according to the thirteenth embodiment, wherein the binder is a make coat.

[0174] In a fifteenth embodiment, the present disclosure provides an abrasive article according to any of the eleventh through fourteenth embodiments, wherein the plurality of first abrasive particles is present and the abrasive article further comprises a size coat disposed on the plurality of first abrasive particles.

[0175] In a sixteenth embodiment, the present disclosure provides an abrasive article according to the fifteenth embodiment, further comprising a supersize coat disposed on the size coat.

[0176] In a seventeenth embodiment, the present disclosure provides an abrasive article according to any of the eleventh through sixteenth embodiments, wherein the plurality of first abrasive particles is present and comprises fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof.

[0177] In an eighteenth embodiment, the present disclosure provides an abrasive article according to any of the eleventh through seventeenth embodiments, wherein the plurality of second abrasive particles is present and comprises fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina or combinations thereof.

[0178] In a nineteenth embodiment, the present disclosure provides a method of making a multilayer substrate. The method comprises applying a liquid polymeric composition on a first major surface of a mesh substrate; pressing a solid substrate against the coated mesh substrate; and curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface. The discontinuous polymeric layer provides a designed surface of the multilayer substrate. Either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

[0179] In a twentieth embodiment, the present disclosure provides a method of making a multilayer substrate. The method comprises applying a liquid polymeric composition on a first major surface of a solid substrate; pressing a mesh substrate against the coated solid substrate; and curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface. The discontinuous polymeric layer provides a designed surface of the multilayer substrate. Either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

[0180] In a twenty -first embodiment, the present disclosure provides a method according to the twentieth embodiment, wherein the liquid polymeric composition is applied on a portion of the first major surface of the solid substrate.

[0181] In a twenty-second embodiment, the present disclosure provides a method according to the twenty -first embodiment, wherein the liquid polymeric composition is applied in a pattern.

[0182] In a twenty -third embodiment, the present disclosure provides a method according to the twenty- second embodiment, wherein the pattern is discontinuous.

[0183] In a twenty-fourth embodiment, the present disclosure provides a method according to any of the twenty -first through twenty -third embodiments, wherein an area coverage of the application of the liquid polymeric composition on the first major surface of the solid substrate is controlled.

[0184] In a twenty -fifth embodiment, the present disclosure provides a method according to the twentieth embodiment, wherein the liquid polymeric composition is applied on the entirety of the first major surface of the solid substrate.

[0185] In a twenty-sixth embodiment, the present disclosure provides a method according to any of the nineteenth through twenty -fifth embodiments, further comprising removing the solid substrate.

[0186] In a twenty-seventh embodiment, the present disclosure provides a method according to any of the nineteenth through twenty-sixth embodiments, wherein the liquid polymeric composition has a shear viscosity of between 50 Pascal seconds (Pa*s) and 2000 Pa*s at a shear rate of 0.1 s'1at 23°C or a shear viscosity between 0.5 Pa*s and 20 Pa*s at a shear rate of 1000 s'1at 23°C.

[0187] In a twenty-eighth embodiment, the present disclosure provides a method according to any of the nineteenth through twenty-seventh embodiments, wherein the liquid polymeric composition has a shear viscosity of between 10 Pa*s and 100 Pa*s at a shear rate of 1 s'1at 38°C or a shear viscosity between 5 to 50 Pa*s at a shear rate of 500 s'1at 38°C.

[0188] In a twenty -ninth embodiment, the present disclosure provides a method according to any of the nineteenth through twenty -eighth embodiments, wherein the liquid polymeric composition is cured using at least one of actinic radiation, thermal curing, or drying.

[0189] In a thirtieth embodiment, the present disclosure provides a method according to any of the nineteenth through twenty -ninth embodiments, wherein the liquid polymeric composition is cured using actinic radiation directed through the mesh substrate.

[0190] In a thirty -first embodiment, the present disclosure provides a method according to any of the nineteenth through thirtieth embodiments, wherein the liquid polymeric composition is cured using actinic radiation directed through the solid substrate.

[0191] In a thirty-second embodiment, the present disclosure provides a method according to any of the nineteenth through thirty -first embodiments, wherein the liquid polymeric composition is coated or patterned using a roll-to-roll process.

[0192] In a thirty -third embodiment, the present disclosure provides a method according to the thirty- second embodiment, wherein the roll-to-roll coating process comprises using a metered application of the liquid polymeric composition onto a coating roll.

[0193] In a thirty-fourth embodiment, the present disclosure provides a method according to any of the nineteenth through thirty -third embodiments, wherein the liquid polymeric composition comprises at least one mineral distributed in a polymeric matrix.

[0194] In a thirty -fifth embodiment, the present disclosure provides a method of making an abrasive article. The method comprises obtaining a multilayer substrate of any of the first through tenth embodiments; and attaching a plurality of first abrasive particles of 36 to 30000 grade in size to the designed surface.

[0195] In a thirty-sixth embodiment, the present disclosure provides a method according to the thirty- fifth embodiment, wherein the attaching the plurality of first abrasive particles comprises: applying a binder to the multilayer substrate; and at least partially embedding the plurality of first abrasive particles in the binder.

[0196] In a thirty-seventh embodiment, the present disclosure provides a method according to the thirtysixth embodiment, further comprising applying a size coat to the plurality of first abrasive particles.

[0197] In a thirty -eighth embodiment, the present disclosure provides a method according to the thirtyseventh embodiment, further comprising applying a supersize coat to the size coat.

[0198] In a thirty -ninth embodiment, the present disclosure provides a method of making an abrasive article, the method comprising making a multilayer substrate according to the method of the thirty -fifth embodiment, wherein the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer, and wherein the mineral comprises a plurality of second abrasive particles of 36 to 30000 grade in size and comprising fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof.

[0199] In a fortieth embodiment, the present disclosure provides a method of making an abrasive article. The method comprises applying a liquid polymeric composition on a first major surface of a mesh substrate, the liquid polymeric composition comprising at least one mineral distributed therein. The method further comprises pressing a solid substrate against the coated mesh substrate, wherein the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer. Additionally, the method comprises curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate.

[0200] In a forty -first embodiment, the present disclosure provides a multilayer substrate according to any of the first through tenth embodiments, wherein the mesh substrate comprises a surface roughness and a base mesh. The surface roughness is a part of the first major surface of the mesh substrate and the discontinuous polymeric layer is present in and / or on the surface roughness without substantially extending down to the base mesh.

[0201] In a forty-second embodiment, the present disclosure provides an abrasive article according to any of the eleventh through eighteenth embodiments, exhibiting a seamless pattern of the discontinuous polymeric layer.

[0202] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

[0203] Furthermore, all publications and patents referenced herein are incorporated by reference in their entirety to the same extent as if each individual publication or patent was specifically and individually indicated to be incorporated by reference. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description prevails. Various exemplary embodiments have been described. These and other embodiments are within the scope of the following claims.EXAMPLES

[0204] Unless otherwise noted or readily apparent from the context, all parts, percentages, ratios, etc., in the Examples and the rest of the specification are by weight.Example 1

[0205] A process as described in FIG. 6 was used to create a multilayer substrate with a controlled surface topography. A UV curable ink, Nazdar NFX52 UV Heavy Deposit Screen Ink (Nazdar Ink Technologies, Shawnee, KS) was coated onto polyethylene terephthalate (PET) solid substrate using a 20 mil notch-bar coating square (BYK Instruments, Wesel, Germany), resulting in a liquid coating thickness approximately 10 mil (254 um) wet film thickness. A mesh substrate (Net MESH GR120 from Sitip S.p. A. (Cena, Italy)) was pressed into the ink such that the first major surface primary fibers contacted the ink. The mesh was peeled away, resulting in the UV curable ink coating the primary fibers but not through to the loop structures on the opposing surface. The mesh was subsequently laminated to a substantially smooth silicone coated substrate obtained from SK Microworks Solutions (Cheonan City, South Korea) such that the ink on the primary fibers was in contact with the silicone coated substrate. The entire sample construction was then passed through a UV curing step. A mercury arc lamp “H bulb” from Fusion UV (acquired by Heraeus Noblelight) was used to sufficiently cure the sample. As the liner utilized was UV transparent, the curing step was performed through the net mesh side of the construction After curing, the silicone coated substrate was removed from the net mesh, resulting in a substantially flat ink polymeric structure on the top surface of the primary fibers as seen in FIGS. 2A and 2B. Thisconstruction was then utilized to create an abrasive product through subsequent resin coating and mineral deposition processes as described in Example 4.

[0206] In an alternative embodiment, this same process was repeated but utilizing an alternative coating material and solidification method. A “hot melt” formulation was utilized that was substantially solid at room temperature but melted to a liquid at approximately 200°F. The formulation was pre-melted in an oven set at 200°F, removed from the oven, and coated with a 20 mil (508 um) coating square onto a PET substrate, which was heated using a hot plate. The mesh substrate was pressed into the hot melt material such that the first major surface primary fibers contacted the material. The mesh was peeled away from the PET, resulting in the hot melt material coating the primary fibers but not through to the loop structures on the opposing surface. The mesh was subsequently laminated to a substantially smooth silicone coated substrate obtained from SK Microworks Solutions such that the ink on the primary fibers was in contact with the silicone coated substrate. The entire sample construction underwent a solidification process by being allowed to cool to room temperature. The silicone coated substrate was removed from the net mesh, resulting in a substantially flat ink structure on the top surface of the primary fibers. Optionally, the sample can be sent through a nip or lamination step prior to the liner removal step or post liner removal. A batch electrostatic coater was used to deposit P600 BFRPL mineral onto the coating on the first major surface. The sample then optionally passed through a secondary solidification step of UV curing with a mercury arc lamp or a UV LED (Phoseon Technology) to create an abrasive product as seen in FIG. 4A.

[0207] Example 2

[0208] A process as outlined in FIG. 6 was used to create a mesh substrate with a discontinuously designed surface topography. An UV-curable screen-printing ink, Nazdar NFX52 UV Heavy Deposit Screen Ink (Nazdar Ink Technologies, Shawnee, KS), was coated onto a polyethylene terephthalate (PET) substrate using a 10 mil notch-bar coating square (BYK Instruments, Wesel, Germany), resulting in a liquid coating thickness approximately 5 mil (127 um) wet film thickness. A mesh substrate (Net MESH GR120 from Sitip S.p.A. (Cena, Italy)) was pressed into the pre-coated donor layer of screen-printing ink such that the first major surface primary fibers contacted the ink. The mesh was peeled away, resulting in the UV-curable ink coating the primary fibers, however, it did not penetrate through to the loop structures on the opposing surface. The ink-coated mesh substrate was subsequently laminated to a three- dimensionally structured polypropylene tooling film - as described in column 20 and Figure 1 of U.S. Patent No. 10,183,379 B2 - such that the UV-curable ink filled the indentations of the structured tooling film locally adjacent to the first major surface primary fibers. The entire sample construction was then transported via a UV conveyor under a mercury arc lamp equipped with an “H bulb” (from Fusion UV, acquired by Heraeus Noblelight), which was used to irradiate the ink, such that it solidified to form discontinuous and three-dimensionally structured polymer on the first major surface primary fibers of the mesh substrate. The tooling film was then peeled from the mesh substrate, resulting in the final article as imaged in FIGS. 3A and 3B.

[0209] Example 3

[0210] A process as outlined in FIG. 6 was used to create a mesh substrate with a discontinuously designed surface topography. An abrasive resin-mineral slurry was first prepared as described in U.S. Patent No. 10, 183,379 B2 (the abrasive slurry “AS-1” found in the Examples section). The abrasive slurry was then coated onto a polyethylene terephthalate (PET) substrate using a 10 mil notch-bar coating square (BYK Instruments, Wesel, Germany), resulting in a liquid coating thickness of approximately 5 mils (127 um). A mesh substrate (Net MESH GR120 from Sitip S.p.A. (Cena, Italy)) was pressed into the pre-coated donor layer of abrasive slurry such that the first major surface primary fibers contacted the abrasive slurry. The mesh was peeled away, resulting in the abrasive slurry coating the primary fibers, however, it did not penetrate through to the loop structures on the opposing surface. The abrasive slurry- coated mesh substrate was subsequently laminated to a three-dimensionally structured polypropylene tooling film - as described in column 20 and Figure 1 of U.S. Patent No. 10,183,379 B2 - such that the UV-curable ink filled the indentations of the structured tooling film locally adjacent to the first major surface primary fibers. The entire sample construction was then transported via a UV conveyor under a mercury arc lamp equipped with an “H bulb” (from Fusion UV, acquired by Heraeus Noblelight) which was used to irradiate the abrasive slurry, such that it solidified to form discontinuous and three- dimensionally structured polymer on the first major surface primary fibers of the mesh substrate. The tooling film was then peeled from the mesh substrate, resulting in the final abrasive article as imaged in FIGS. 5A, 5B, and 5C.Example 4

[0211] A coating apparatus generally as illustrated in FIG. 10 was used. A steel metering roll, a rubber coated coating roll, and a steel impression roll was installed into a coating station of a continuous webprocessing line obtained from Retroflex, Inc. Each roll was independently driven and allowed to rotate in either a clockwise or counterclockwise orientation. For the configuration seen in FIG. 10, the impression roll was driven in the counterclockwise direction while both the coating roll and metering roll were driven in the clockwise direction. The surface speed of each roll was allowed to be varied as a roll speed ratio relative to the webline speed.

[0212] A doctor blading system was applied to the metering roll in a skiving configuration as seen in FIG. 10. The blade holder and blade were mechanically loaded against the metering roll so that when the roll was rotating, the blade was wiping away a significant portion of the coating solution.

[0213] A continuous mesh substrate (Net MESH GR120 from Sitip S.p.A. (Cena, Italy)) was threaded into the web processing line to bring the back loop surface into contact with the impression roll so that the first major surface was facing the coating roll.

[0214] A UV curable, Nazdar NFX52 UV Heavy Deposit Screen Ink (Nazdar Ink Technologies, Shawnee, KS) coating solution was applied to the top nip gap between the metering roll and coating roll via hand pouring of the formulation from a container or with the use of a pumping system. A 630 seriescased peristaltic pumping system from Watson Marlow was utilized. The coating roll and metering roll were positioned sufficiently close together such that for the viscosity of the solution used, delivery of the solution to the top of the nip created pond or rolling bank of solution as seen in FIG. 12. A substantially continuous layer of coating solution was seen on the coating roll where the thickness of said coating was dictated by process conditions including solution rheology, the distance or gap between the coating roll and metering roll, and the speed ratio of the metering roll relative to the coating roll. The coating roll and impression roll were positioned sufficiently close together such that for the viscosity of the solution used, a coating solution transferred from the coating roll to a continuous substrate. The amount of coating solution transferred and its placement onto the substrate is a result of process conditions including solution rheology, the distance or gap between the coating roll and impression roll, and the properties of the substrate.

[0215] Subsequently, the top or faceside of the solution coated substrate was brought into contact with an idler roll (approximately 6 inches in diameter) wrapped with a silicone coated substrate obtained from SK Microworks Solutions. While the coated substrate was in contact with the silicone wrapped idler, the coating solution was cured through the mesh by means of a UV curing source. In an alternative embodiment, the coated surface could be brought into contact with a silicone roll and the coating solution was cured by means of a UV curing source. In another embodiment, a liner could be applied, and the construction cured through either the primary surface or the secondary backside of the mesh, or both.

[0216] A UV LED curing unit (FJ100 obtained from Phoseon Technology) was placed between 0.5 and 3 inches from the outer surface of the substrate in a location like that shown in FIG. 12. The UV system was turned on and set to an intensity setting (1.5 W / cmA2 to 6 W / cmA2) such that the solution coated substrate, when in contact with the silicone substrate, reached a cure level where the solution coated on the substrate was substantially solid, particularly at the surface in contact with the silicone substrate so much as the solution coated substrate cleanly removed from the silicone substrate.

[0217] An optional secondary UV curing step can be utilized to ensure sufficient curing of the coated solution on the substrate.

[0218] Subsequently, the created controlled surface structure mesh was used to make an abrasive article with the following procedure. An abrasive article was achieved by applying make resin onto the top surface of the article using a roll coater. The make resin was prepared by dissolving 59.6 parts by weight RES, 2 parts BDK, and 18 parts TMPTA. To this solution mixture was added 20 parts by weight of water; and 0.4 parts by weight BP. The roll coater, having a steel top roller and a rubber bottom roller immersed in the make coat, was obtained from Eagle Tool, Inc., Minneapolis, MN. The amount of make coat transferred to the surface was adjusted until only the top surface sample was coated or approximately 40 grams per square meter. The make coated mesh was gelled by irradiation with an ultraviolet (UV) lamp, LED 365 nm bulb, from Excelitas Technologies (Mississauga, ON)., at 20 ft / min and 600 mJW. The make coated disc was weighed and P600 mineral was applied using an electrostatic coater. Following coating, the coated mesh was cured in an oven at 225°F for 45 minutes.

[0219] After curing, the size resin was coated using a roll coater. The size resin was prepared by dissolving 84 parts by weight RES, 0.2 parts BP, and 15.8 parts by weight water. The roll coater, having a steel top roller and a rubber bottom roller immersed in the size coat, was obtained from Eagle Tool, Inc., Minneapolis, MN. The diluted size coat resin was applied continuously over the patterned printed area and discontinuously over the non-abrasive area of the mesh. Once coated, the size coated mesh was cured in an oven set at 225°F for 2 hours.

[0220] Details on the specific materials used are included in Table 1 below.

[0221] Table 1

[0222] Abrasive articles were evaluated for tensile strength and abrasive performance. Tensile strength was measured via a Dynamic Mechanical Analysis (DMA) machine (Instron 5900 Series. Model number is 2736-015). The samples under evaluation were cut into 1.5 x 6 inch rectangles and enclosed in a DMA jaw, with 3 inches between DMA jaws. The sample was pulled at 1000 mm / min until sample failure. The recorded values of Young’s modulus (average slope value from 0.2 mm to 20 mm elongation) were recorded and used for comparison.

[0223] Abrasive performance of the abrasive articles made were evaluated on 18 inch by 18 inch corian panels. For testing purposes, the abrasive discs of 6-inch diameter were attached to a 6-inch interface pad, commercially available under the trade designation “Festool Interface Pad IP-STF D150 / MJ2-5 / 2”PN 30092, from 3M Company, St. Paul, MN. The interface pad was secured to a “Festool compressed air eccentric sander LEX3 15 / 5” PN 29951, from 3M Company, St. Paul, MN. The sander was attached to a “Festool Mobile Dust Extractor Cleantec CT 36” PN 29947, from 3M Company, St. Paul, MN. The inlet air pressure going to the Festool mobile unit was set to 60 PSI and the sander rpm control lever was set to wide open.

[0224] Sanding was performed along the 18 inches width direction moving the sander in a back-and- forth motion at a speed of approximately 1 foot / second. Stroke length was approximately 16 inches and the downward force on the sander was approximately 20 lbs. An abrasive disc was sanded in this manner for 1 minute before moving 6 inches over on the panel along the 24 inches width direction. Each minute of sanding is considered one cycle. A total of 2 cycles were performed on each sample. The mass of the panel was measured before and after each cycle to determine the mass loss from the OEM panel in grams after each cycle. Total cut was determined as the cumulative mass loss at the end of the test.

[0225] Finish was evaluated with a profilometer after a single cycle of sanding, taking an average of six Rz measurements to determine abrasive article finish performance.

[0226] Variations

[0227] Numerous variations of the above-described example were performed. Some experiments included different release surfaces. The roll for which the surface of the solution coated substrate is brought into contact with can be constructed from a releasable material such as silicone, or surface coated or wrapped in a releasable material such as a silicone liner so the solution coated substrate removes cleanly from the roll or rolls. Additionally, the roll or rolls can optionally include a texture or pattern to create a deliberate texture or pattern onto the surface of the solution coated substrate. Some experiments used different mesh substrates.

[0228] Some experiments used different coating solutions. A coating solution that is substantially solid or of an unacceptably high viscosity for this coating process at “room temperature” (70°F) but that drops in viscosity upon heating can be utilized in a temperature-controlled configuration. This coating solution was heated to conduct the coating process, including any potential combination of heating the solution in its starting container, heating the delivery lines to the coating station, heating the coating station components including the rolls and / or doctor blades, heating the local environment of the coating station, and / or heating the substrate. Additionally, components can be selectively cooled to achieve the desired solution coating process, including the rolls in the coating station and / or the substrate. After the coating step, the surface of the solution coated substrate can then optionally be brought into contact with one or more rolls, idlers or driven, or optionally a nip, to further control the surface of the coating. The rolls can be temperature-controlled to heat and / or cool the solution coated substrate to achieve the desired surface. Optionally this process can be coupled with a UV curing step if needed by the coating solution. The roll or rolls can be constructed from a releasable material or coated or wrapped in a releasable material so the solution coated substrate removes cleanly from the roll or rolls. Additionally, the roll or rolls can optionally include a texture or pattern to create a deliberate texture or pattern onto the surface of the solution coated substrate.Example 5

[0229] A process as described in FIG. 9 was used to create a net backing with a controlled surface topography. A UV curable ink NFX52 was printed onto a silicone coated substrate obtained from SK Microworks Solutions using a stencil printing process. This process included placing a 3 mil thick PET stencil, created by laser cutting to form a discontinuous pattern, onto the silicone coated substrate then blading the UV curable ink across the stencil and removing the stencil to leave a pattern coating behind on the silicone substrate. A mesh substrate was then laminated to the silicone substrate so that the primary fibers of the mesh were at least partially submerged in the UV curable ink but not contacting the secondary fibers. This entire stack was then UV cured by sending it on a conveyor under an H bulb light available from Fusion UV (acquired by Heraeus Noblelight) so that it was sufficiently cured. This curing was done with both the mesh side facing the light and the silicone coated substrate side facing the light. After curing the silicone coated substrate was removed from the mesh substrate resulting in discontinuous patterned planarized features like those shown in FIG. 10D.

[0230] Example 6

[0231] A process as described in FIG. 9 was used to create a net backing with a controlled surface topography. A UV curable ink NFX52 was printed onto a structured polypropylene film as described in Example 2 using a stencil printing process. This process included placing a 3 mil thick PET stencil, created by laser cutting to form a discontinuous pattern, onto the polypropylene film then blading the UV curable ink across the stencil and removing the stencil to leave a pattern coating behind on the polypropylene substrate. A mesh substrate was then laminated to the polypropylene substrate so that the primary fibers of the mesh were at least partially submerged in the UV curable ink but not contacting the secondary fibers. This entire stack was then UV cured by sending it on a conveyor under an H bulb light available from Fusion UV (acquired by Heraeus Noblelight) so that it was sufficiently cured. This curing was done with the mesh side facing the light. After curing the polypropylene substrate was removed from the mesh substrate resulting in discontinuous patterned structured features like those shown in FIG. 11D.

[0232] Example 7

[0233] A process as described in G. 9 was used to create a net backing with a controlled surface topography. A UV curable ink NFX52 mixed at a ratio of 1 : 1 with GC2500 Green SiC (Fujimi Corp, Elmhurst, IL) was printed onto a stmctured polypropylene film as described in Example 2 using a stencil printing process. This process included placing a 3 mil thick PET stencil, created by laser cutting to form a discontinuous pattern, onto the polypropylene film then blading the UV curable ink across the stencil and removing the stencil to leave a pattern coating behind on the polypropylene substrate. A mesh substrate was then laminated to the polypropylene substrate so that the primary fibers of the mesh were at least partially submerged in the UV curable ink but not contacting the secondary fibers. This entire stack was then UV cured by sending it on a conveyor under an H bulb light available from Fusion UV (acquired by Heraeus Noblelight) so that it was sufficiently cured. This curing was done with the mesh side facing the light. After curing the polypropylene substrate was removed from the mesh substrate resulting in discontinuous patterned structured features like those shown in Figure 1 ID containing abrasive mineral.

[0234] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

[0235] Furthermore, all publications and patents referenced herein are incorporated by reference in their entirety to the same extent as if each individual publication or patent was specifically and individuallyindicated to be incorporated by reference. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description prevails. Various exemplary embodiments have been described. These and other embodiments are within the scope of the following claims.

Claims

What is claimed is:

1. A multilayer substrate comprising: a mesh substrate having a first major surface and an opposing major surface; and a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate, wherein the discontinuous polymeric layer has a first major surface that is opposite the mesh substrate; and either: a) wherein the first major surface of the discontinuous polymeric layer comprises a planar surface, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) wherein the first major surface of the discontinuous polymeric layer comprises a patterned structured surface.

2. The multilayer substrate of claim 1, wherein the mesh substrate is in a form of a net comprising a plurality of each of primary fibers, secondary fibers, and tertiary fibers.

3. The multilayer substrate of claim 2, comprising a plurality of gaps between adjacent portions of the discontinuous polymeric layer located between adjacent primary fibers.

4. The multilayer substrate of any of claims 1 to 3, wherein the discontinuous polymeric layer comprises a phenolic polymer, a urea-formaldehyde polymer, a (methjacrylic polymer, an epoxy polymer, an epoxy acrylate polymer, or combinations thereof.

5. The multilayer substrate of any of claims 1 to 4, wherein the discontinuous polymeric layer comprises at least one mineral distributed in a polymeric matrix.

6. The multilayer substrate of any of claims 1 to 5, wherein the mesh substrate comprises a woven fabric or a knitted fabric.

7. The multilayer substrate of any of claims 1 to 6, exhibiting a surface area of 20% or greater than the mesh substrate alone.

8. The multilayer substrate of any of claims 1 to 7, exhibiting a Young's modulus that is at least 50% larger than the mesh substrate alone.

9. The multilayer substrate of any of claims 1 to 8, wherein the first major surface of the discontinuous polymeric layer comprises a planar surface, wherein the designed surface exhibits an average flatness of 50 micrometers or less.

10. The multilayer substrate of any of claims 1 to 8, wherein the first major surface of the discontinuous polymeric layer comprises a patterned structured surface.

11. The multilayer substrate of any of claims 1 to 10, wherein the mesh substrate comprises a surface roughness and a base mesh, wherein the surface roughness is a part of the first major surface of the mesh substrate, and wherein the discontinuous polymeric layer is present in and / or on the surface roughness without substantially extending down to the base mesh.

12. An abrasive article comprising: the multilayer substrate of any of claims 1 to 11; and at least one of: i) a plurality of first abrasive particles of 36 to 30000 grade in size attached to the designed surface; or ii) a plurality of second abrasive particles of 36 to 30000 grade in size distributed in the discontinuous polymeric layer.

13. The abrasive article of claim 12, wherein the plurality of first abrasive particles is present and of 600 to 2000 grade in size.

14. The abrasive article of claim 12 or claim 13, further comprising a binder disposed on the designed surface, wherein the plurality of first abrasive particles is present and at least partially embedded in the binder.

15. The abrasive article of claim 14, wherein the binder is a make coat.

16. The abrasive article of any of claims 12 to 15, wherein the plurality of first abrasive particles is present and the abrasive article further comprises a size coat disposed on the plurality of first abrasive particles.

17. The abrasive article of claim 16, further comprising a supersize coat disposed on the size coat.

18. The abrasive article of any of claims 12 to 17, wherein the plurality of first abrasive particles is present and comprises fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof.

19. The abrasive article of any of claims 12 to 18, wherein the plurality of second abrasive particles is present and comprises fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof.

20. The abrasive article of any of claims 12 to 19, exhibiting a seamless pattern of the discontinuous polymeric layer.

21. A method of making a multilayer substrate, the method comprising: applying a liquid polymeric composition on a first major surface of a mesh substrate; pressing a solid substrate against the coated mesh substrate; and curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate, wherein either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

22. A method of making a multilayer substrate, the method comprising: applying a liquid polymeric composition on a first major surface of a solid substrate; pressing a mesh substrate against the coated solid substrate; and curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate, wherein either: a) the solid substrate has a planar major surface that imparts flatness to an exterior surface of the discontinuous polymeric layer, wherein the designed surface exhibits an average flatness of 50 micrometers or less; or b) the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer.

23. The method of claim 22, wherein the liquid polymeric composition is applied on a portion of the first major surface of the solid substrate.

24. The method of claim 23, wherein the liquid polymeric composition is applied in a pattern.

25. The method of claim 24, wherein the pattern is discontinuous.

26. The method of any of claims 23 to 25, wherein an area coverage of the application of the liquid polymeric composition on the first major surface of the solid substrate is controlled.

27. The method of claim 22, wherein the liquid polymeric composition is applied on the entirety of the first major surface of the solid substrate.

28. The method of any of claims 21 to 27, further comprising removing the solid substrate.

29. The method of any of claims 21 to 28, wherein the liquid polymeric composition has a shear viscosity of between 50 Pa*s and 2000 Pa*s at a shear rate of 0.1 s'1at 23°C or a shear viscosity between 0.5 Pa*s and 20 Pa*s at a shear rate of 1000 s'1at 23°C.

30. The method of any of claims 21 to 28, wherein the liquid polymeric composition has a shear viscosity of between 10 Pa*s and 100 Pa*s at a shear rate of 1 s'1at 38°C or a shear viscosity between 5 to 50 Pa*s at a shear rate of 500 s'1at 38°C.

31. The method of any of claims 21 to 30, wherein the liquid polymeric composition is cured using at least one of actinic radiation, thermal curing, or drying.

32. The method of any of claims 21 to 31, wherein the liquid polymeric composition is cured using actinic radiation directed through the mesh substrate.

33. The method of any of claims 22 to 32, wherein the liquid polymeric composition is cured using actinic radiation directed through the solid substrate.

34. The method of any of claims 21 to 33, wherein the liquid polymeric composition is coated or patterned using a roll-to-roll process.

35. The method of claim 34, wherein the roll-to-roll coating process comprises using a metered application of the liquid polymeric composition onto a coating roll.

36. The method of any of claims 21 to 35, wherein the liquid polymeric composition comprises at least one mineral distributed in a polymeric matrix.

37. A method of making an abrasive article, the method comprising: obtaining the multilayer substrate of any of claims 1 to 11; and attaching a plurality of first abrasive particles of 36 to 30000 grade in size to the designed surface.

38. The method of claim 37, wherein the attaching the plurality of first abrasive particles comprises: applying a binder to the multilayer substrate; and at least partially embedding the plurality of first abrasive particles in the binder.

39. The method of claim 38, further comprising applying a size coat to the plurality of first abrasive particles.

40. The method of claim 39, further comprising applying a supersize coat to the size coat.

41. A method of making an abrasive article, the method comprising making a multilayer substrate according to the method of claim 37, wherein the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer,and wherein the mineral comprises a plurality of second abrasive particles of 36 to 30000 grade in size and comprising fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, or combinations thereof.

42. A method of making an abrasive article, the method comprising: applying a liquid polymeric composition on a first major surface of a mesh substrate, the liquid polymeric composition comprising at least one mineral distributed therein; pressing a solid substrate against the coated mesh substrate, wherein the solid substrate has a patterned structured major surface that imparts an inverse pattern to an exterior surface of the discontinuous polymeric layer; and curing the liquid polymeric composition, thereby forming a discontinuous polymeric layer disposed on an exterior of the first major surface, wherein the discontinuous polymeric layer provides a designed surface of the multilayer substrate.

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