WO2025159753A1

WO2025159753A1 - Patterned abrasive article

Info

Publication number: WO2025159753A1
Application number: PCT/US2024/012973
Authority: WO
Inventors: JR. Javad RESHAD; Christoper A. ALI
Original assignee: Rust Oleum Corp
Current assignee: Rust Oleum Corp
Priority date: 2024-01-25
Filing date: 2024-01-25
Publication date: 2025-07-31
Anticipated expiration: 2026-07-25

Abstract

Described herein is a patterned abrasive article. The patterned abrasive article includes a substrate defining a first surface and a second opposite surface and an abrasive layer positioned relative to at least the second surface of the substrate. The abrasive layer defines a pattern including a plurality of raised abrasive features. The substrate defines, either directly or indirectly, a plurality of channels positioned relative to each of the plurality of raised abrasive features. Each of the plurality of raised abrasive features defines three tips and two pairs of angled sides.

Description

PATTERNED ABRASIVE ARTICLE

FIELD OF THE DISCLOSURE

[0001] The present disclosure is directed to an abrasive article, and more particularly, to a patterned abrasive article.

BACKGROUND

[0002] Conventional abrasive articles include abrasive materials on a planar surface, an example of which is sandpaper. Existing abrasive articles often clog with the material being removed from a work surface, which causes a reduction in material removal and an increase in work time and cost.

[0003] Thus, there is a need for a higher performing abrasive article that provides improved material removal and reduces clogging.

BRIEF DESCRIPTION OF THE DISCLOSURE

[0004] In one embodiment of the present disclosure, provided herein is a patterned abrasive article including a substrate defining a first surface and a second opposite surface and an abrasive layer positioned relative to at least the second surface of the substrate, the abrasive layer defining a pattern including a plurality of raised abrasive features. The substrate defines, either directly or indirectly, a plurality of channels positioned relative to each of the plurality of raised abrasive features. Each of the plurality of raised abrasive features defines three tips and two pairs of angled sides.

[0005] In another embodiment of the present disclosure, provided herein is a patterned abrasive article including a substrate defining a working surface, and an abrasive layer positioned relative to the working surface of the substrate. The abrasive layer and the substrate define a pattern including a plurality of raised abrasive features and a plurality of channels. The pattern includes a plurality of alternating rows, the plurality of alternating rows includes a first set of rows and a second set of rows, wherein the plurality of raised abrasive features are positioned in a first direction in the first set of rows and a second opposite direction in the second set of rows. The plurality of channels are positioned between each of the plurality of raised abrasive features within the first set of rows and the second set of rows of the plurality of alternating rows, and between each of the plurality of raised abrasive features positioned within each row of the plurality of alternating rows.

[0006] In another embodiment of the present disclosure, provided herein is a method of manufacturing a patterned abrasive article including a substrate defining a working surface, and an abrasive layer positioned relative to the working surface of the substrate. The abrasive layer and the substrate define a pattern including a plurality of raised abrasive features and a plurality of channels. The method includes applying a binder base layer to the working surface of the substrate in accordance with the pattern. The method includes applying an abrasive to at least the binder base layer, such that the abrasive is at least partially embedded within the binder base layer. Each of the plurality of raised abrasive features is defined by the binder base layer and the abrasive.

[0007] Any combination or permutation of features, functions, and/or embodiments as disclosed herein is envisioned. Additional advantageous features, functions, and applications of the disclosed systems, methods, and assemblies of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following figures are examples of a patterned abrasive article in accordance with the present disclosure and are not to be construed as limiting.

[0009] Various example embodiments may be more completely understood in consideration of the following detailed description and in connection with the accompanying drawings, in which:

[0010] Fig. 1 is a top view of a patterned abrasive article, according to the present disclosure.

[0011] Fig. 2 is a top view of the patterned abrasive article shown in Fig. 1 taken within detail 1 , illustrating a portion of the patterned abrasive article. [0012] Fig. 3 is a cross-sectional view of the patterned abrasive article shown in Figs. 1 and 2 taken along line A-A.

[0013] Fig. 4A is a detailed top view of the patterned abrasive article shown in Fig. 1 , according to the present disclosure.

[0014] Fig. 4B is an enhanced detailed top view of the patterned abrasive article shown in Fig. 4A.

[0015] Fig. 5 A is a detailed top view of one embodiment of the patterned abrasive article shown in Fig. 1, according to the present disclosure.

[0016] Fig. 5B is an enhanced detailed top view of the patterned abrasive article shown in Fig. 5A.

[0017] Fig. 6 is a flow chart illustrating a method of manufacturing the patterned abrasive article shown in the figures.

[0018] Fig. 7 is a bar graph depicting the quantity of material removed in grams for each of the four test samples, as it relates to Example 1.

[0019] Fig. 8 is an image depicting the removal of material from a steel plate after each round of testing for each of the four test samples, as it relates to Example 1.

[0020] Fig. 9 is a bar graph depicting the quantity of material removed in grams for each of the two test samples, as it relates to Example 2.

DETAILED DESCRIPTION

[0021] Described herein is a patterned abrasive article. The patterned abrasive article may be configured for a variety of applications, including but not limited to, grinding, sanding, polishing, buffing, and roughening a work piece or other item. The patterned abrasive article may be flexible so as to at least partially conform to a work piece, a tool, a user’s hand, or related item.

[0022] While various embodiments discussed herein are amenable to modifications and alternative forms, aspects thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention of the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure including aspects defined in the claims.

[0023] Referring to Figs. 1-3, a patterned abrasive article 10 includes a substrate 12 and an abrasive layer 14. The patterned abrasive article 10 may be sized and shaped for a variety of applications. For example, the patterned abrasive article 10 may be shaped in a variety of geometric shapes, including but not limited to, a circle, a rectangle, a triangle, a square, an irregular shape, and combinations thereof. The patterned abrasive article 10 may be patterned with a variety of geometric shapes, including but not limited to, circles, rectangles, squares, triangles, ellipses, lines, irregular shapes, and combinations thereof. The patterned abrasive article may be sized and shaped as a sheet, a disc, a sponge, a belt, and combinations thereof. The abrasive layer 14 of the patterned abrasive article 10 may have a grit range that extends between sanding and polishing. For example, the abrasive layer 14 of the patterned abrasive article 10 may have a grit range of about 40 grit to about 4,000 grit.

[0024] The substrate 12 is positioned to support at least a portion of the abrasive layer 14, either directly or indirectly. In some instances, the substrate 12 may be sized and positioned to support the abrasive layer 14 in its entirety such that the size and shape of the substrate 12 is similar to or larger than the abrasive layer 14. The substrate 12 may be fabricated from a variety of materials, including but not limited to, paper, cloth, film, sponge, foam, net, and combinations thereof. The substrate 12 defines at least a first surface 16 and a second opposite surface 18. The first surface 16 may be configured to interface with a tool (not shown), a user’s hand (not shown), a holding device (not shown), and variations thereof, either directly or indirectly. For example, the first surface 16 of the substrate 12 may include one or both components of a hook-and-loop attachment system (not shown). The substrate may include vent holes (not shown) in fluid communication with, for example, a tool (not shown). The second surface 18 may be configured to interface with the abrasive layer. In some instances, the abrasive layer 14 may be applied directly to the second surface 18 of the substrate 12. In some instances, the abrasive layer 14 maybe applied indirectly to the second surface 18 of the substrate 12. [0025] The abrasive layer 14 may include one or more layers of material, consistent with the intended application, as noted above. Therefore, the following description of the abrasive layer 14 is not intended to limit this disclosure to a specific application, but instead provides one or more examples of the patterned abrasive article 10. Referring to Fig. 3, the abrasive layer 14 is positioned relative to the second surface 18 of the substrate 12, either directly or indirectly. The abrasive layer 14 includes an abrasive 20 and a binder base layer 22. The abrasive 20 may be selected from the group including, but not limited to, aluminum oxide, zirconium, ceramic alumina, silicon carbide, and combinations thereof. The binder base layer 22 may bind the abrasive 20 to the substrate, either directly or indirectly. The binder base layer 22 may be an adhesive, a resin, and variations thereof. The binder base layer 22 may be selected from the group including, but not limited to, urea formaldehyde (UF), phenol-formaldehyde (PF), epoxy resin, and combinations thereof. In some instances, the abrasive 20 may be at least partially embedded within the binder base layer 22. A binder top layer 24 may at least partially engage with the abrasive 20 and/or the binder base layer 22 of the abrasive layer 14. The abrasive 20 may be at least partially encapsulated by the binder top layer 24. As depicted, the binder top layer 24 may also engage with the substrate 12, for example, the second surface 18 of the substrate 12. The binder top layer 24 may be an adhesive, a resin, and variations thereof. The binder top layer 24 may be selected from the group including, but not limited to, urea formaldehyde (UF), phenol-formaldehyde (PF), epoxy resin, and combinations thereof.

[0026] As noted above, the patterned abrasive article 10 may be patterned with a variety of geometric shapes, including but not limited to, circles, rectangles, squares, triangles, ellipses, lines, irregular shapes, and combinations thereof. Referring to Figs. 1-3, the patterned abrasive article 10 may define a plurality of raised abrasive features 26. The plurality of raised abrasive features 26 are defined, at least in part, by the abrasive layer 14. The plurality of raised abrasive features 26 of the abrasive layer 14 may be spaced in a pattern so as to define a plurality of channels 28. The plurality of channels 28 are defined, at least in part, by the substrate 12.

[0027] Referring specifically to Fig. 2, the plurality of channels 28 separate each of the plurality of raised abrasive features 26. Fig. 2 is a detailed view of Fig. 1 and highlights two pairs of the plurality of raised abrasive features 26, with the remaining pairs depicted in dashed form. The plurality of raised abrasive features 26 may be alternatingly positioned such that a first raised abrasive feature 26A is pointed in a first direction and a second raised abrasive feature 26B is pointed in a second direction. The first and second raised abrasive features 26A, 26B may be oppositely positioned relative to each other (see, e.g., Fig. 2). It should be understood that other raised abrasive features 26, not specifically identified by 26A or 26B, are similar to the identified raised abrasive features 26A, 26B. Accordingly, unless otherwise indicated, the description related to raised abrasive features 26A, 26B also applies to the other raised abrasive features 26 of the patterned abrasive article 10. As a result, reference number 26 will continue to be used to refer to the raised abrasive features 26. Similarly, any reference numbers designated with an A, a B, or the like will also refer to the reference numbers without the letter modifier, unless otherwise indicated.

[0028] Each of the plurality of raised abrasive features 26 may resemble a triangular shape, a tooth-like shape (e.g., a shark tooth-like shape), a reptilian scale-like shape (e.g., an alligator scale-like shape), an arrowhead-like shape, and combinations or variations thereof. The raised abrasive features 26 may define one or more sharp comers. For example, the raised abrasive features 26 may define a plurality of sharp corners. Although the raised abrasive features 26 and, subsequently, the plurality of channels 28 are depicted with sharp corners, it should be understood that the raised abrasive features 26 and/or the plurality of channels 28 may define one or more radiused comers.

[0029] In one embodiment and referring to Fig. 2, the raised abrasive feature 26 defines a shape having a first tip 32 on a first end 36. Specifically, the first raised abrasive feature 26A defines a shape having the first tip 32A that extends to a point, and similarly, the second raised abrasive feature 26B defines a shape having the first tip 32B that extends to a point. The raised abrasive feature 26 defines a shape having two second tips 34 on a second end 38, which is opposite the first end 36. Specifically, the first raised abrasive feature 26A defines a shape having two second tips 34A that extends to a point, and similarly, the second raised abrasive feature 26B defines a shape having two second tips 34B that extends to a point. The two second tips 34 are spaced a distance from each other and at an angle relative to the first tip 32. The first tip 32 and the two second tips 34 may embody a triangle-like shape. The raised abrasive feature 26 defines a shape having an indent 30 on the second end 38 that is positioned between the two second tips 34 and extends in a direction toward the first end 36. Specifically, the first raised abrasive feature 26A defines a shape having the indent 30A that extends to a point, and similarly, the second raised abrasive feature 26B defines a shape having the indent 30B that extends to a point. The indent 30 is at an angle relative to the two second tips 34 and spaced at a distance from the first tip 32.

[0030] The raised abrasive feature 26 defines a shape having two first sides 40, where one of the two first sides extends between the first tip 32 and one of the two second tips 34 and the second of the two first sides extends between the first tip 32 and the other of the two second tips 34. Specifically, the first raised abrasive feature 26A defines a shape having two first sides 40A, where each of the two first sides 40A are angled relative to each other extending between the first tip 32A and the corresponding second tip 34A. Similarly, the second raised abrasive feature 26B defines a shape having two first sides 40B, where each of the two first sides 40B are angled relative to each other extending between the first tip 32B and the corresponding second tip 34B. The raised abrasive feature 26 defines a shape having two second sides 42, where each of the two second sides 42 extends between the indent 30 and one of the two second tips 34. Specifically, the first raised abrasive feature 26A defines a shape having two second sides 42A, where each of the two second sides 42A are angled relative to each other extending between the indent 30A and the corresponding second tip 34A. Similarly, the second raised abrasive feature 26B defines a shape having two second sides 42B, where each of the two second sides 42B are angled relative to each other extending between the indent 30B and the corresponding second tip 34B. The two first sides 40A, 40B of the first and second raised abrasive feature 26A, 26B may at least in part define the plurality of channels 28. The two second sides 42A, 42B of the first and second raised abrasive feature 26A, 26B may at least in part define the plurality of channels 28. The two first sides 40A, 40B and the two second sides 42A, 42B of the first and second raised abrasive feature 26A, 26B may at least in part define the plurality of channels 28.

[0031] Referring specifically to Fig. 3, the plurality of raised abrasive features 26 of the abrasive layer 14 may be raised relative to the plurality of channels 28 of the substrate 12, in a direction opposite the second surface 18 of the substrate 12. The plurality of raised abrasive features 26 of the abrasive layer 14 may define a height that is greater than the plurality of channels 28 of the substrate 12. The height of the plurality of raised abrasive features 26 relative to the plurality of channels 28 may, at least in part, depend on the intended application of the patterned abrasive article 10. For example, in sanding applications, the patterned abrasive article 10 with a finer grit may define a height of the plurality of raised abrasive features 26 that is shorter than the patterned abrasive article 10 with a rougher grit. In some instances, and as depicted in Fig. 3, the plurality of raised abrasive features 26 of the abrasive layer 14 and the plurality of channels 28 of the substrate 12 may include the binder top layer 24. The height of the plurality of raised abrasive features 26 relative to the plurality of channels 28 (also referred to as the channel 28 depth) is between about 0.0055 inches and about 0.0255 inches. The width of the plurality of channels 28 relative to adjacent raised abrasive features 26 is between about 0.0135 inches and about 0.0415 inches. In a non-limiting example, the channel 28 depth may be about 0.025 inches and the channel 28 width may be about 0.041 inches. In another non-limiting example, the channel 28 depth may be about 0.017 inches and the channel 28 width may be about 0.030 inches. In another non-limiting example, the channel 28 depth may be about 0.014 inches and the channel 28 width may be about 0.021 inches. In another non-limiting example, the channel 28 depth may be about 0.007 inches and the channel 28 width may be about 0.015 inches. In another non-limiting example, the channel 28 depth may be about 0.006 inches and the channel 28 width may be about 0.014 inches. It should be understood, however, that various combinations of channel 28 widths and depths may be implemented without departing from the spirit/ scope of this disclosure.

[0032] The patterned abrasive article 10 may be sized and shaped for a variety of applications. The plurality of raised abrasive features 26 are spaced relative to each other by the plurality of channels 28. Depending on the shape of the raised abrasive features 26, some of the following dimensions may not apply while other dimensions will apply. The following are not intended to be limiting or constraining, but merely provides context to one or more embodiments.

[0033] Referring to Figs. 4A and 4B, the first raised abrasive feature 26A and the second raised abrasive feature 26B are positioned in an alternating pattern such that the first tip 32A of the first raised abrasive feature 26A and the two second tips 34B of the second raised abrasive feature 26B are roughly in line with each other, and similarly, the second tips 34A of the first raised abrasive feature 26A are roughly in line with the first tip 32B of the second raised abrasive feature 26B. The distance between the indents 30A of the two adjacent first raised abrasive features 26A is identified as reference number 52 and is between about 0.7 inches “in” (17.78 millimeters “mm”) and about 0.9 in (22.86 mm). Similar to distance 52, the distance between the indents 30B of the two adjacent second raised abrasive features 26B is between about 0.7 in (17.78 mm) and about 0.9 in (22.86 mm). The distance between the first tips 32B of the second raised abrasive feature 26B is identified as reference number 54 and is between about 0.7 in (17.78 mm) and about 0.9 in (22.86 mm). Similar to distance 54, the distance between the first tips 32A of the first raised abrasive feature 26A is between about 0.7 in (17.78 mm) and about 0.9 in (22.86 mm). In some instances, the distance 52 may be equal to or nearly equal to the distance 54 for the first and second raised abrasive features 26A, 26B.

[0034] Referring to the first raised abrasive feature 26A, the distance between the two second tips 34A is identified as reference number 56 and is between about 0.59 in (14.97 mm) and about 0.63 in (16.00 mm). The distance between the indent 30A and the first tip 32A of the first raised abrasive feature 26A is identified as reference number 58 and is between about 0.45 in (11.43 mm) and about 0.52 in (13.21 mm). Referring to the second raised abrasive feature 26B, the distance between the two second tips 34B is identified as reference number 60 and is between about 0.59 in (14.97 mm) and about 0.63 in (16.00 mm). The distance between the indent 30B and the first tip 32B of the second raised abrasive feature 26B is identified as reference number 62 and is between about 0.45 in (11.43 mm) and about 0.52in (13.21 mm).

[0035] Referring to the first and second raised abrasive features 26A, 26B and the channel 28, the distance between the first side 40A of the first raised abrasive feature 26A and the first side 40B of the second raised abrasive feature 26B is identified as reference number 64 and is between about 0.07 in (1.78 mm) and about 0.10 in (2.54 mm). Referring to the first and second raised abrasive features 26A, 26B and the channel 28, the distance between the second side 42A of the first raised abrasive feature 26A and the second side 42B of the second raised abrasive feature 26B is identified as reference number 66 and is between about 0.07 in (1.78 mm) and about 0.10 in (2.54 mm).

[0036] Referring to two adjacent second raised abrasive feature 26B in axial alignment, the distance between the first tip 32B of one of the two second raised abrasive features 26B and the first tip 32B of the second of the two second raised abrasive features 26B is identified as reference number 68 and is between about 0.65 in (16.51 mm) and about 0.69 in (17.53 mm). Similar to distance 68, the distance between the first tip 32A of one of the two first raised abrasive features 26A and the first tip 32A of the second of the two first raised abrasive features 26A is between about 0.65 in (16.51 mm) and about 0.69 in (17.53 mm).

[0037] Referring to the first raised abrasive feature 26A, the angle of the first sides 40A relative to each other is identified as reference number 70 and is between about 45 degrees and about 49 degrees. Simar to angle 70, the angle between the first sides 40B of the second raised abrasive feature 26B relative to each other is between about 45 degrees and about 49 degrees. Referring to the first raised abrasive feature 26A, the angle of the second sides 42A relative to each other is identified as reference number 72 and is between about 115 degrees and about 119 degrees. Similar to angle 72, the angle between second sides 42B of the second raised abrasive feature 26B relative to each other is between about 115 degrees and about 119 degrees.

[0038] Referring to the second raised abrasive feature 26B, the angle of the first side 40B relative to the second side 42B is identified as reference number 74 and is between about 33 degrees and about 37 degrees. Simar to angle 74, the angle of the first side 40A relative to the second side 42 A of the first raised abrasive feature 26A is between about 33 degrees and about 37 degrees.

[0039] Figs. 5A and 5B illustrate one embodiment of the patterned abrasive article 10 and is not intended to be limiting on the rest of the disclosure. The first raised abrasive feature 26A and the second raised abrasive feature 26B are positioned in an alternating pattern such that the first tip 32A of the first raised abrasive feature 26A and the two second tips 34B of the second raised abrasive feature 26B are roughly in line with each other, and similarly, the second tips 34A of the first raised abrasive feature 26A are roughly in line with the first tip 32B of the second raised abrasive feature 26B. The distance between the indents 30A of the two adjacent first raised abrasive features 26A is identified as reference number 52 and is about 0.80 inches “in” (about 20.3 millimeters “mm”). Similar to distance 52, the distance between the indents 30B of the two adjacent second raised abrasive features 26B is about 0.80 in (about 20.3 mm). The distance between the first tips 32B of the second raised abrasive feature 26B is identified as reference number 54 and is about 0.80 in (about 20.3 mm). Similar to distance 54, the distance between the first tips 32A of the first raised abrasive feature 26A is about 0.80 in (about 20.3 mm). In some instances, the distance 52 may be equal to or nearly equal to the distance 54 for the first and second raised abrasive features 26 A. 26B.

[0040] Referring to the first raised abrasive feature 26A, the distance between the two second tips 34A is identified as reference number 56 and is about 0.61 in (about 15.6 mm). The distance between the indent 30A and the first tip 32A of the first raised abrasive feature 26A is identified as reference number 58 and is about 0.51 in (about 13.1 mm). Referring to the second raised abrasive feature 26B, the distance between the tw o second tips 34B is identified as reference number 60 and is about 0.61 in (about 15.6 mm). The distance between the indent 30B and the first tip 32B of the second raised abrasive feature 26B is identified as reference number 62 and is about 0.52 in (about 13. 1 mm).

[0041] Referring to the first and second raised abrasive features 26A, 26B and the channel 28, the distance between the first side 40A of the first raised abrasive feature 26A and the first side 40B of the second raised abrasive feature 26B is identified as reference number 64 and is about 0.09 in (about 2.2 mm). Referring to the first and second raised abrasive features 26A, 26B and the channel 28, the distance between the second side 42A of the first raised abrasive feature 26A and the second side 42B of the second raised abrasive feature 26B is identified as reference number 66 and is about 0.09 in (about 2.2 mm).

[0042] Referring to two adjacent second raised abrasive feature 26B in axial alignment, the distance between the first tip 32B of one of the two second raised abrasive features 26B and the first tip 32B of the second of the two second raised abrasive features 26B is identified as reference number 68 and is about 0.67 in (about 17.1 mm). Similar to distance 68, the distance between the first tip 32A of one of the two first raised abrasive features 26A and the first tip 32A of the second of the two first raised abrasive features 26A is about 0.67 in (about 17.1 mm).

[0043] Referring to the first raised abrasive feature 26A, the angle of the first sides 40A relative to each other is identified as reference number 70 and is about 47 degrees. Similar to angle 70, the angle between the first sides 40B of the second raised abrasive feature 26B relative to each other is about 47 degrees. Referring to the first raised abrasive feature 26A, the angle of the second sides 42A relative to each other is identified as reference number 72 and is about 117 degrees. Similar to angle 72, the angle between second sides 42B of the second raised abrasive feature 26B relative to each other is about 117 degrees. [0044] Referring to the second raised abrasive feature 26B, the angle of the first side 40B relative to the second side 42B is identified as reference number 74 and is about 35 degrees. Similar to angle 74, the angle of the first side 40A relative to the second side 42A of the first raised abrasive feature 26A is about 35 degrees.

[0045] In use, the plurality of channels 28 may capture and/or redirect dust away from the plurality of raised abrasive features 26 so as to reduce clogging of the abrasive layer 14. The sharp comers of the raised abrasive features 26 may promote faster cutting power. The plurality of channels 28 may encourage airflow between the plurality of raised abrasive features 26 so as to reduce the surface temperature of at least the abrasive layer 14 during use. The patterned abrasive article 10 including a plurality of raised abrasive features 26 may include a reduced quantity of abrasive material 20 and binder 22, 24 when compared with standard non-pattemed abrasive articles of similar size and shape. For example, the patterned abrasive article 10 may utilize between about 20 and about 25 percent less abrasive material and binder than a standard non-pattemed abrasive article of similar size and shape.

[0046] The method of creating the patterned abrasive article 10 includes identifying the desired pattern of the plurality of raised abrasive features 26. The desired pattern may include, but is not limited to, the size, location, and design of the raised abrasive features 26. The desired pattern, for example the pattern illustrated in Figs. 1-5, is etched onto an applicator (not shown). The applicator may include an applicator roll, for example, a rubber roll, a steel roll, a ceramic roll, and combinations thereof. A predetermined amount of the binder base layer 22 is applied to the applicator roll. The substrate 12 of the patterned abrasive article 10 is positioned in contact with the applicator roll (not shown) such that the binder base layer 22 is applied to the substrate 12 in the desired pattern. The abrasive 20 is distributed over the substrate 12, for example, over the entirety⁷ of the substrate 12. The substrate 12 retains the abrasive 20 in the areas where the binder base layer 22 was applied and creates the raised abrasive features 26, which represent the desired pattern. The portion of the substrate without the binder base layer 22 and the abrasive 20 are the plurality of channels 28. In some instances, a binder top layer 24 may be applied over at least the abrasive 20 and the binder base layer 22. The outcome is the patterned abrasive article 10 including the plurality of raised abrasive features 26 and the plurality of channels 28. The method for producing the patterned abrasive article 10 may include a tolerance for the size of the raised abrasive features 26, the tolerance may be about +/- 30 percent. The method for producing the patterned abrasive article 10 may include a tolerance for the size of the plurality of channels 28, the tolerance may be about +/- 15 percent. The patterned abrasive article 10 may be manufactured using a gravure coating technique. In a non-limiting example, the method of creating the patterned abrasive article 10 may include utilizing the Gravure coating technique.

[0047] In one embodiment and referring to Fig. 6. a method of creating a patterned abrasive article 10 includes, at step 102, identifying a desired pattern for the patterned abrasive article 10. Then, at step 104, applying a binder (e.g., the binder base layer 22) in the desired pattern to the substrate 12 of the patterned abrasive article 10. The binder base layer 22 may be applied to the substrate using an applicator roll (not shown). Finally, at step 106, applying the abrasive 20 to the substrate 12. The abrasive 20 may bind to only the binder base layer 22, thereby creating the raised abrasive features 26. The areas without the binder base layer 22 and the abrasive 20 are referred to as the plurality⁷ of channels 28.

Example 1

[0048] The following evaluation of the patterned abrasive article 10, as described herein, is not intended to be limiting, but instead provides a showing of superior performance. For this evaluation, the goal was to determine which abrasive article removes the most material from a steel plate.

[0049] Parameters: The test substrate was a painted steel plate. Four painted steel plates were used, one for each of the four (4) test samples. The test equipment was an automated random orbital sander. It is an industry standard to compare patterned abrasive articles to flat abrasive articles, thus three of the four samples were flat abrasive articles. Test sample 1 was the patterned abrasive article 10, as illustrated in the figures. Test sample 2 was a flat sandpaper from Diablo® (High Point. NC, USA). Test sample 3 was a flat sandpaper from the Applicant. Test sample 4 was a flat sandpaper from the Applicant. The four samples were 5-inch diameter hook and loop discs that attached to the automated random orbital sander. Each of the four samples included a ceramic mix abrasive that was 80 grit. [0050] Experiment: Each test sample was positioned to contact with the corresponding steel plate for five (5) minutes per round. Each test sample was exposed to four (4) rounds for a total of twenty (20) mmutes of exposure with the steel plate. The amount in weight of the paint and metal that was removed was collected.

[0051] Results: In conclusion and referring to Fig. 7, test sample 1, which was the patterned abrasive article 10, as described herein, removed in total, 13.01 grams, which is about 9 percent more weight than test sample 2 and test sample 3. Test sample 1 removed about 38 percent more weight than test sample 4. Fig. 8 shows the surface of the painted steel plate after each round. As depicted, test sample 1 fully removed the paint from the painted steel plate, whereas test samples 2-4 left paint after some of the rounds. The numbers depicted on each steel plate are the amount in weight (grams) of the paint and metal that was removed after each round. The round number is identified in the top left comer of each steel plate. Test sample 1 displays superior performance longevity by removing a significant amount of material across the four (4) rounds, as compared to test samples 2-4.

Example 2

[0052] The following evaluation of the patterned abrasive article 10, as described herein, is not intended to be limiting, but instead provides a showing of superior performance. For this evaluation, the goal was to determine which abrasive article removes the most material from a steel plate.

[0053] Parameters: The test substrate was a steel plate coated with putty/body filler. Two (2) coated steel plates were used, one for each of the two (2) test samples. The test equipment was an automated random orbital sander. It is an industry⁷ standard to compare patterned abrasive articles to flat abrasive articles, thus one of the two samples was a flat abrasive article. Test sample I was the patterned abrasive article 10. as illustrated in the figures. Test sample 2 was a flat sandpaper from Diablo* (High Point, NC, USA). The two samples were 5-inch diameter hook and loop discs that attached to the automated random orbital sander. Each of the two samples included a ceramic mix abrasive that was 80 grit. [0054] Experiment: Each test sample was positioned to contact with the corresponding steel plate for 30 seconds per round. Each test sample was exposed to three (3) rounds for a total of 90 seconds of exposure with the steel plate. The amount in weight of the paint and metal that was removed was collected and measured after each round.

[0055] Results: In conclusion and referring to Fig. 9. test sample 1 removed in total about 8 grams more than test sample 2. The quantity of material was collected and measured after 30 seconds, 60 seconds, and 90 seconds. After 30 seconds, test sample 1 and test sample 2 removed 8 grams of material each. After 60 seconds, test sample 1 removed about 14 grams of material and test sample 2 removed about 12 grams of material. After 90 seconds, test sample 1 removed about 23 grams of material and test sample 2 removed about 16 grams of material. In total, test sample 1 removed about 44 grams of material and test sample 2 removed about 36 grams of material.

[0056] Based upon the above discussion and illustrations, those skilled in the art will readily recognize that various modifications and changes may be made to the various embodiments without strictly following the exemplary embodiments and applications illustrated and described herein. For example, the patterned abrasive article may be utilized for a multitude of different types of sanding, scuffing, and polishing applications on a variety of surfaces. Further, the embodiments noted herein may be combined, and further embodiments may be separated. Alternative comer shapes, such as rounded comers, pointed comers, square comers, and combinations thereof may be used for the patterned abrasive article. Such modifications do not depart from the scope of various aspects of the invention, including aspects set forth in the claims.

[0057] This written description uses examples to illustrate the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have stmctural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. [0058] As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains”, “containing,” “characterized by” or any other variation thereof, are intended to cover a non-exclusive inclusion, subject to any limitation explicitly indicated. For example, a composition, mixture, process or method that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such composition, mixture, process or method.

[0059] The transitional phrase “consisting of’ excludes any element, step, or ingredient not specified. If in the claim, such would close the claim to the inclusion of materials other than those recited except for impurities ordinarily associated therewith. When the phrase “consisting of’ appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0060] The transitional phrase “consisting essentially of’ is used to define a composition or method that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel characteristic(s) of the claimed disclosure. The term “consisting essentially of’ occupies a middle ground between “comprising” and “consisting of’.

[0061] Where a disclosure or a portion thereof is defined with an open- ended term such as “comprising,” it should be readily understood that (unless otherwise stated) the description should be interpreted to also describe such a disclosure using the terms “consisting essentially of’ or “consisting of.”

[0062] Further, unless expressly stated to the contrary’, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0063] Also, the indefinite articles “a” and “an” preceding an element or component of the disclosure are intended to be nonrestrictive regarding the number of instances (i.e., occurrences) of the element or component. Therefore “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

[0064] As used herein, the term “about” refers to a measurable value such as a parameter, an amount, a temporal duration, and the like and is meant to include variations of +/- 15% or less, preferably variations of +/- 10% or less, more preferably variations of +/- 5% or less, even more preferably variations of +/- 1% or less, and still more preferably variations of +/- 0.1% or less of and from the particularly recited value, in so far as such variations are appropriate to perform in the invention described herein. Furthermore, it is also to be understood that the value to which the modifier “about” refers is itself specifically disclosed herein.

[0065] As used herein, spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper”, “front”, “back”, “side”, “left”, “right”, “rear”, “top”, “bottom”, and the like, are used for ease of description to describe one element or feature’s relationship to another element(s) or feature(s). It is further understood that the terms “front”, “back”, “left”, and “right” are not intended to be limiting and are intended to be interchangeable, where appropriate. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or relative importance, but rather are used to distinguish one element from another.

[0066] As used herein, the terms “configure(s)”, “configuring”, and the like, refer to the capability of a component and/or assembly, but do not preclude the presence or addition of other capabilities, features, components, elements, operations, and any combinations thereof.

[0067] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. Each range disclosed herein constitutes a disclosure of any point or sub-range lying w ithin the disclosed range.

[0068] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”), is intended merely to better illustrate the invention and does not pose a limitation on the scope of the invention or any embodiments unless otherwise claimed. [0069] While the invention has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for the elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt the teaching of the invention to particular use, application, manufacturing conditions, use conditions, composition, medium, size, and/or materials without departing from the essential scope and spirit of the invention. Therefore, it is intended that the invention is not limited to the exemplary embodiments and best mode contemplated for carrying out this invention as described herein. Since many modifications, variations, and changes in detail can be made to the described examples, it is intended that all matters in the preceding description and shown in the accompanying figures be interpreted as illustrative and not in a limiting sense.

Claims

WHAT IS CLAIMED IS:

1. A patterned abrasive article, comprising: a substrate defining a first surface and a second opposite surface; and an abrasive layer positioned relative to at least the second surface of the substrate, the abrasive layer defining a pattern comprising a plurality of raised abrasive features, wherein the substrate defines, either directly or indirectly, a plurality of channels positioned relative to each of the plurality of raised abrasive features, and wherein each of the plurality’ of raised abrasive features defines three tips and two pairs of angled sides.

2. The patterned abrasive article of claim 1. wherein each of the plurality of raised abrasive features defines a first tip with a first pair of the two pairs of angled sides extending therefrom, the first pair of the two pairs of angled sides angled relative to each other and extending between the first tip and two second tips, the second pair of the two pairs of angled sides extending from the two second tips in a direction towards a central axis of each of the plurality of raised abrasive features, the second pair of the two pairs of angled sides are angled relative to each other and extending between one of the two second tips and an indent.

3. The patterned abrasive article of claim 2, wherein the first tip and the indent are positioned along the central axis of each of the plurality of raised abrasive features.

4. The patterned abrasive article of claim 1. wherein each of the plurality of raised abrasive features is defined as a reptilian scale-like shape.

5. The patterned abrasive article of claim 1, wherein the pattern comprises a plurality of alternating rows, the plurality of alternating rows comprises a first set of rows and a second set of rows, wherein the plurality of raised abrasive features are positioned in a first direction in the first set of rows and a second opposite direction in the second set of rows.

6. The patterned abrasive article of claim 5, wherein the plurality of channels are positioned between each of the plurality of raised abrasive features within the first set of rows and the second set of rows of the plurality of alternating rows, and between each of the plurality of raised abrasive features positioned within each row of the plurality of alternating rows.

7. The patterned abrasive article of claim 1. wherein the three tips are pointed.

8. The patterned abrasive article of claim 1, wherein the substrate is selected from the group consisting of, paper, cloth, film, sponge, foam, net, and combinations thereof.

9. The patterned abrasive article of claim 1, wherein the abrasive layer defines a grit range between about 40 grit and about 4,000 grit.

10. The patterned abrasive article of claim 1, wherein each of the plurality of raised abrasive features of the abrasive layer comprises a binder base layer positioned relative to the substrate and a plurality' of abrasives embedded at least partially within the binder base layer.

11. The patterned abrasive article of claim 10 further comprising a binder top layer positioned relative to the binder base layer and the plurality of abrasives of the plurality of raised abrasive features and the plurality of channels of the substrate.

12. A patterned abrasive article comprising a substrate defining a working surface, and an abrasive layer positioned relative to the working surface of the substrate, the abrasive layer and the substrate defining a pattern comprising a plurality of raised abrasive features and a plurality' of channels, the pattern comprising: a plurality of alternating rows, the plurality of alternating rows comprising a first set of rows and a second set of rows, wherein the plurality of raised abrasive features are positioned in a first direction in the first set of rows and a second opposite direction in the second set of rows; and the plurality' of channels are positioned between each of the plurality of raised abrasive features within the first set of rows and the second set of rows of the plurality of alternating rows, and between each of the plurality of raised abrasive features positioned within each row of the plurality of alternating rows.

13. The patterned abrasive article of claim 12, wherein each of the plurality of raised abrasive features is defined as a reptilian scale-like shape.

14. The patterned abrasive article of claim 12, wherein the three tips are pointed.

15. The patterned abrasive article of claim 12, wherein each of the plurality of raised abrasive features defines a first tip with a first pair of the two pairs of sides extending therefrom, the first pair of the two pairs of sides angled relative to each other and extending between the first tip and two second tips, the second pair of the two pairs of sides extending from the two second tips in a direction towards a central axis of each of the plurality of raised abrasive features, the second pair of the two pairs of sides are angled relative to each other and extending between one of the two second tips and an indent.

16. The patterned abrasive article of claim 15, wherein the first pair of the two pairs of sides are angled relative to each other at an angle between about 45 degrees and about 49 degrees.

17. The patterned abrasive article of claim 15, wherein the second pair of the two pairs of sides are angled relative to each other at an angle between about 115 degrees and about 119 degrees.

18. The patterned abrasive article of claim 12, wherein relative to the substrate, each of the plurality of raised abrasive features has a height greater than each of the plurality of channels.

19. A method of manufacturing a patterned abrasive article comprising a substrate defining a working surface, and an abrasive layer positioned relative to the working surface of the substrate, the abrasive layer and the substrate defining a pattern comprising a plurality of raised abrasive features and a plurality of channels, the method comprising: applying a binder base layer to the working surface of the substrate in accordance with the pattern; and applying an abrasive to at least the binder base layer, such that the abrasive is at least partially embedded within the binder base layer. wherein each of the plurality of raised abrasive features is defined by the binder base layer and the abrasive.

20. The method of claim 19 further comprising applying a binder top layer over the plurality of the raised abrasive features and the working surface of the substrate.