BACKGROUND

It is very common for dry sanding operations to generate a significant amount of airborne dust. To minimize this airborne dust, it is common to use abrasive discs on a tool while vacuum is drawn through the abrasive disc, from the abrasive side through the backside of the disc, and into a dust-collection system. For this purpose, many abrasives are available with holes converted into them, to facilitate this dust extraction. As an alternative to converting dust-extraction holes into abrasive discs, commercial products exist in which the abrasive is coated onto fibers of a mesh backing in which loops are knit into the backside of the abrasive article. The loops serve as the loop-portion of a hook-and-loop (fastener) attachment system for attachment to a tool. Net type products are known to provide superior dust extraction and/or anti-loading properties, when used with substrates known to severely load traditional abrasives. However, cut and/or life performance are still lacking. Thus, there is a need for a net type product that provides enhanced cut and/or life performance while demonstrating superior dust extraction.

BRIEF SUMMARY

In at least one embodiment, the cut of net abrasives can be marked by low cut performance and low durability.

Aspects of the present disclosure relate to a method of making an abrasive article to improve the cut performance and durability. The method can include providing a combination of a mesh backing and a fastener. The mesh backing has a first side and a second side and the mesh backing has a fastener disposed on the second side and intertwined through the mesh backing therein. The combination comprises a raised portion on the first side having a first dimension. The method can include calendering the first side of the mesh backing to form a calendered mesh backing such that the raised portion results in a second dimension. The second dimension is less than the first dimension. The method can include depositing a curable make layer precursor on a major surface of the calendered mesh backing, deposing a plurality of abrasive particles onto the curable make layer precursor, and at least partially curing the curable make layer precursor.

Additional aspects of the present disclosure relate to an abrasive article made according to the method. Additional aspects relate to a system that includes a calendering system configured to receive a combination comprising a mesh backing and a fastener, the calendering system comprising a tensioner, an upper roll, and a lower roll. The upper roll and the lower roll are configured to apply a pressure and a temperature to the combination, a first temperature of the upper roll and a second temperature of the lower roll are different. The coating system configured to coat a make layer, abrasive particles, and a size layer onto a calendered combination.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

FIG. 1A illustrates a cross-sectional view of an abrasive article in accordance with one embodiment.

FIG. IB illustrates an elevational view of the abrasive article in accordance with one embodiment.

FIG. 2 illustrates a system of making an abrasive article in accordance with one embodiment.

FIG. 3 illustrates a method of making an abrasive article in accordance with one embodiment.

FIG. 4A illustrates an aspect of the subject matter in accordance with one embodiment.

FIG. 4B illustrates an aspect of the subject matter in accordance with one embodiment.

FIG. 5 illustrates an aspect of the subject matter in accordance with one embodiment. FIG. 6 illustrates an aspect of the subject matter in accordance with one embodiment. FIG. 7 illustrates a sample profile graph of mesh backings in accordance with one embodiment.

FIG. 8 illustrates an example pattern of an abrasive article in accordance with one embodiment.

DETAILED DESCRIPTION

Aspects of the present disclosure relate to calendering a mesh backing before applying a make resin and abrasive particles to form an abrasive article. FIG. 1A and FIG. IB illustrate a coated abrasive article 100. The coated abrasive article 100 can be for a net or mesh abrasive.

The abrasive article 100 can include a combination 106 and an abrasive portion 122. The combination 106 comprises a mesh backing 102 and fastener 104 intertwined with the mesh backing 102. The mesh backing 102 and/or a portion of the fastener 104 of the combination 106 can be calendered according to the process described herein.

The mesh backing 102 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 backing 102 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. In at least one embodiment, the mesh backing 102 can have an average size of 0.5 square millimeters. In at least one embodiment, the mesh backing 102 can have an open area of at least 40%, at least 50%, even at least 60%. In at least one embodiment, the mesh backing 102 can have an initial open area of between 40% and 60% (inclusive).

In at least one embodiment, the mesh backing 102 can also include a sizing agent.

If the mesh backing 102 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 backing 102 can have a yam thickness of at least 100 micrometers, at least 150 micrometers, at least 300 micrometers, at least 300 micrometers, or at least 350 micrometers. In another measurement, the yarn can have a total denier of no greater than 3000 deniers, no greater than 1000 deniers, no greater than 500 deniers. In at least one embodiment, the yarn can have a breaking tenacity of at least X300 mN/tex as measured by ASTM D2256. The mesh backing 102 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 backing 102 can have a fabric weight of at least 40 gsm.

In at least one embodiment, the mesh backing 102 can be mostly planar and a plane of mesh backing 102 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 yarn 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. In at least one embodiment, the calendering can result in a calendered combination having a decreased raised portion relative to the combination as determined using the Raised Portion Topological Profile Method described herein. In at least one embodiment, the height differential of the calendered combination can decrease at least 50 percent, at least 60 percent, or at least 70 percent relative to the combination (as a result of calendering) as determined by the Raised Portion Topological Profile Method.

If the mesh backing 102 is a woven fabric, then the mesh backing 102 can have at least 2 ends per inch and no greater than 20 ends per inch.

A woven fabric mesh backing 102 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.

If the mesh backing 102 is a knitted fabric, then the mesh backing 102 can have no greater than 2 stiches per square inch. In at least one embodiment, the mesh backing 102 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 stich 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 stich and/or the feet of another stich can form the raised portion of the mesh backing 102. 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 stiches 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 yarn according to ASTM D2256(2021).

In at least one embodiment, the topology of the combination 106 can be indicated by the coefficient of friction. The coefficient of friction can be determined using Coefficient of Friction Test Method described herein. For example, the max KP in the machine direction of a calendered mesh backing can be no greater than 0.4. In at least one embodiment, the max KP in the machine direction of the calendered mesh backing can be at least a 25% decrease relative to the max KP in the machine direction of a comparable uncalendered mesh backing. In some embodiments, the mesh backing 102 has a mechanical fastener, or adhesive fastener securely attached to a major surface opposite the abrasive layer.

A fastener 104 is shown as included in the combination 106. The fastener 104 can be disposed on the side 120 which is opposite from the side 118.

The fastener 104 can be a mechanical fastener which is part of a hook-and-loop system, or thread/filament/yam sewn to the substrate of interest. In at least one embodiment, the mechanical fastener can be a loop portion of the hook-and-loop system. The loop portion of a hook-and-loop-fastener can be provided integral with the absorbent article. In at least one embodiment, the loops provided in the mesh backing 102 can interact with the hooks of a hook-portion of the mechanical fastener. For example, the loop portion can be stitched through/interwoven with the side 120 of the mesh backing 102. In at least one embodiment, the attachment thread of the loop portion (proximate the feet of the loop) can be raised relative to a plane of the side 118 as described above. For example, if the mesh backing 102 is extruded, then the attachment thread of the loop portion (formed on side 120) can cross through the holes formed in the mesh backing 102 so that the stitch of the attachment thread forms a raised portion on side 118 thereby securing the fastener 104 to the mesh backing 102.

In at least one embodiment, the attachment thread of the loop portion can be stitched through the yam of the mesh backing 102 (if fabric) such that the attachment thread is not protruding from the side 118.

An aspect of the present disclosure is that the combination 106 undergoes melt roll calendering prior to depositing a make layer 108. The melt roll calendering process can be described further herein.

The abrasive portion 122 of the abrasive article 100 can be formed according to "Abrasive Article", Li et. al., published as PCT Publication WO 2021/116882 on 17 June 2021 or “Coated Abrasive Articles and Methods of Making Coated Abrasive Articles” by Liu et. al., published as PCT WO 2021/116883 on 17 June 2021. In at least one embodiment, the abrasive article 100 can include optional laminate film 110 that is applied to the combination 106. The make layer 108 can be deposited on the laminate film 110.

For example, the abrasive article 100 can include a make layer 108 which is shown as a continuous layer. In at least one embodiment, the make layer 108 can be formed from discrete, discontinuous sections of make resin. The discontinuous sections comprising the make layer 108 can be approximately the same thickness relative to the mesh backing 102. The make layer 108 is disposed on and bonded to side 118 of the mesh backing 102. In at least one embodiment, some of the make layer 108 can coat the sections of the mesh backing 102 surrounding holes formed in the mesh backing 102.

Abrasive particles 112 can be disposed on the make layer 108 so that the abrasive particles 112 can maintain their position while abrading a surface. A size layer 114 can be disposed over and bonded to make layer 108, and abrasive particles 112. Optional supersize layer 116 or other functional layers are disposed over and bonded to size layer 114.

The make layer, size layer and the optional supersize layer comprise a resinous binder which may be the same or different. Exemplary suitable binders can be prepared from corresponding binder precursors such as thermally curable resins, radiation-curable resins, and combinations thereof.

Binder precursors (e.g., make layer precursors and/or size layer precursors) may comprise, for example, glue, phenolic resin, aminoplast resin, urea-formaldehyde resin, melamine-formaldehyde resin, urethane resin, free-radically polymerizable polyfunctional (meth)acrylate (e.g., aminoplast resin having pendant a,P-unsaturated groups, acrylated urethane, acrylated epoxy, acrylated isocyanurate), epoxy resin (including bis-maleimide and fluorene -modified epoxy resins), isocyanurate resin, and mixtures thereof. Of these, phenolic resins are preferred, especially when used in combination with a vulcanized fiber backing.

Phenolic resins are generally formed by condensation of phenol and formaldehyde, and are usually categorized as resole or novolac phenolic resins. Novolac phenolic resins are acid-catalyzed and have a molar ratio of formaldehyde to phenol of less than 1: 1. Resole (also resol) phenolic resins can be catalyzed by alkaline catalysts, and the molar ratio of formaldehyde to phenol is greater than or equal to one, typically between 1.0 and 3.0, thus presenting pendant methylol groups. Alkaline catalysts suitable for catalyzing the reaction between aldehyde and phenolic components of resole phenolic resins include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, and sodium carbonate, all as solutions of the catalyst dissolved in water.

Resole phenolic resins are typically coated as a solution with water and/or organic solvent (e.g., alcohol). Typically, the solution includes about 70 percent to about 85 percent solids by weight, although other concentrations may be used. If the solids content is very low, then more energy is required to remove the water and/or solvent. If the solids content is very high, then the viscosity of the resulting phenolic resin is too high which typically leads to processing problems.

Phenolic resins are well-known and readily available from commercial sources. Examples of commercially available resole phenolic resins useful in practice of the present disclosure include those marketed by Durez Corporation under the trade designation VARCUM (e.g., 29217, 29306, 29318, 29338, 29353); those marketed by Ashland Chemical Co. of Bartow, Florida under the trade designation AEROFENE (e.g., AEROFENE 295); and those marketed by Kangnam Chemical Company Ltd. of Seoul, South Korea under the trade designation PHENOLITE (e.g, PHENOLITE TD-2207).

Binder precursors can further comprise optional additives such as, for example, fillers (including grinding aids), fibers, lubricants, wetting agents, surfactants, pigments, dyes, coupling agents, resin curatives, plasticizers, antistatic agents, and suspending agents. Examples of fillers suitable for this invention include wood pulp, vermiculite, and combinations thereof, metal carbonates, such as calcium carbonate, e.g, chalk, calcite, marl, travertine, marble, and limestone, calcium magnesium carbonate, sodium carbonate, magnesium carbonate; silica, such as amorphous silica, quartz, glass beads, glass bubbles, and glass fibers; silicates, such as talc, clays (montmorillonite), feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate; metal sulfates, such as calcium sulfate, barium sulfate, sodium sulfate, aluminum sodium sulfate, aluminum sulfate; gypsum; vermiculite; wood flour; aluminum trihydrate; metal oxides, such as calcium oxide (lime), aluminum oxide, titanium dioxide, and metal sulfites, such as calcium sulfite.

Binder precursors may be applied by any known coating method, including, for example, including roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

The basis weight of the make layer utilized may depend, for example, on the intended use(s), type(s) and grade(s) of abrasive particles, and nature of the coated abrasive disc being prepared, but typically will be in the range of from 1, 2, 5, 10, or 15 grams per square meter (gsm) to 20, 25, 100, 300, 300, 400, or even 600 gsm.

FIG. 2 illustrates a system 200 and FIG. 3 illustrates a method 300 for making the abrasive article of this disclosure (e.g., abrasive article 100). Reference will be made to both FIG. 3 and FIG. 2.

For example, the method 300 can begin at block 302 where the combination is received. The combination can be received with the fastener or without the fastener attached. If the fastener is not attached, then one action may be attaching the fastener to the mesh backing.

In block 304, the system 200 can calender the combination. The system 200 can use a calendering system 216 that includes upper roll 204, lower roll 206, and tensioner 208. The calendering system 216 can perform the calendering on the combination 214 in accordance with this disclosure to form the calendered combination 210. The calendering system 216 can calender the calendered combination 210 (which is similar to combination 106).

The rolls, upper roll 204 and lower roll 206, can advance the combination 214 through the system 200. In at least one embodiment, the upper roll 204 can have a first temperature and the lower roll 206 can have a second temperature. For example, the first temperature can be at least 350 degrees Fahrenheit (176 degrees Celsius) or at least 400 degrees Fahrenheit (204 degrees Celsius) and the first temperature is no greater than the melting point of the material (e.g., 500 degrees Fahrenheit or 260 degrees Celsius). The second temperature can be at least 200 degrees Fahrenheit (93 degrees Celsius).

In at least one embodiment, the tensioner 208 can apply tension to a roll of the combination 214 to aid in the calendering. The line speed can determine the degree of energy transfer to the combination 214. For example, the line speed can range from 5 feet/minute to 25 feet/minute (inclusive). In at least one embodiment, the upper roll 204 and the lower roll 206 can have pressure applied such that the applied pressure is at least 40, at least 200, at least 400, or at least 500 pounds per linear inch.

In at least one embodiment, alternative calendering methods can be used such as friction calendering and pattern calendering.

After calendering to form the calendered combination 210, the coating system 202 can deposit the make layer precursor in block 306 as described in Li et. al. In block 308, the coating system 202 can deposit the abrasive particles onto the make layer. In block 310, the coating system 202 can cure the curable make layer precursor to harden the resin with the abrasive particles. In block 312, the coating system 202 can apply the size layer. In block 314, the coating system 202 can apply any functional layers, such as a supersize layer.

FIG. 4A and FIG. 4B illustrate a combination 400 that includes the mesh backing 404 and a mechanical fastener 402.

The mesh backing 404 is shown as a knitted fabric comprising a first yam having a plurality of stiches interwoven together. Stich 408 can include a head 406 formed by looping the first yam around the legs of another stich. The stich 408 can include leg 410 which is connected to foot 416 and leg 412 which is connected to foot 414. As shown, the knitted fabric can have a half-tricot knit having closed laps.

The mechanical fastener 402 is depicted as a plurality of loops that correspond to a hook-and-loop fastener. The hook-and-loop fastener can have a second yam (shown as having a single filament) that is knit through the mesh backing 404. For example, each loop of the fastener can have a closed lap and be interwoven with the mesh backing 404. As shown, the knit pattern of the fastener is a weft knit with the loops arranged in the cross direction.

FIG. 5 illustrates a combination 500 highlighting the mesh backing 504. The mesh backing 504 can have a raised portion 502 formed from the head and at least two yam segments (e.g., the legs). The raised portion 502 can have a first dimension.

FIG. 6 illustrates a combination 600 showing the mesh backing 504 in a calendered state. The calendered raised portion 602 of the mesh backing 504 has a second dimension. In at least one embodiment, the second dimension and first dimension can be height relative to a plane of the mesh backing. The height of the calendered raised portion 602 can be less than the height of the raised portion 502. In at least one embodiment, the height of the calendered raised portion 602 can decrease at least 65% from the height of the raised portion 502 in response to the calendering. In at least one embodiment, the first dimension and the second dimension can represent at least one measurement in a direction parallel to the plane of the mesh backing. For example, width or length of the raised portion can be taken. In at least one embodiment, the width or length of the raised portion (e.g., largest measurement taken along a plane of the raised portion can be a dimension) can increase from the raised portion 502 to the calendered raised portion 602. Thus, the calendering of mesh backing 504 (mesh backing 604) can have a decrease in the percent open area of the mesh backing 604 by at least 20 percent relative to mesh backing 504 or an increase in the percent surface area of the mesh backing 604 by at least 20 percent, at least 22 percent, at least 25 percent, or at least 27 percent.

In at least one embodiment, the coefficient of friction can be decreased by at least 10 percent, at least 12 percent, at least 20 percent, or at least 30 percent. For example, the coefficient of friction kinetic potential can be determined based off of the machine direction or the cross-direction.

EXAMPLES

Advantages and embodiments of this invention are further illustrated by the following examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this invention. Foreseeable modifications and alterations of this disclosure will be apparent to those skilled in the art without departing from the scope and spirit of this invention. All parts and percentages are by weight unless otherwise indicated.

Unless otherwise noted, all parts, percentages, ratios, etc. in the Examples and the rest of the specification are by weight. The following abbreviations may be used: m = meters; cm = centimeters; mm = millimeters; um = micrometers; ft = feet; in = inch; RPM = revolutions per minute; g = grams; mg = milligrams; kg = kilograms; oz = ounces; lb = pounds; mb = milliliter; L = liter; Pa = Pascals; kPa = kilopascals; sec = seconds; min = minutes; hr = hours; psi = pounds per square inch; °C = degrees Celsius; °F = degrees Fahrenheit; and phr = parts (by weight) per hundred of resin. The terms “weight %”, “% by weight”, and “wt%” are used interchangeably. The abbreviation “mesh” indicates a “combination” as used herein.

Materials

The materials are listed in Table 1.

Table 1 - Materials

Trade Fabric

Abbreviation Description Supplier

Designation Weight

Half-tricot, closed lap Net MESH Sitip S.p.A.

Mesh A 85 gsm knit with interwoven GR85/90 (Cena, Italy) weft knit loops

Half-tricot, closed lap

Net MESH 106 Sitip S.p.A.

Mesh B knit with interwoven

GR120 H100 gsm (Cena, Italy) weft knit loops

Blue Net

Half-tricot, closed lap Scott and Fyfe

Mesh 135 135

Mesh C knit with interwoven Ltd. (Fife, gsm, Batch gsm weft knit loops Scotland) H3025010-1

Half-tricot, closed lap

Net MESH 150 Sitip S.p.A.

Mesh D knit with interwoven

GR150 H100 gsm (Cena, Italy) weft knit loops Trade Fabric

Abbreviation Description Supplier

Designation Weight

Half-tricot, closed lap Scott and Fyfe

Net MESH 220

Mesh E knit with interwoven Ltd. (Fife,

GR220 gsm weft knit loops Scotland)

A base -catalyzed (2.5% KOH) 1.5: 1 to 2.1: 1 phenol¬

ECI formaldehyde condensate, 75% in water.

Valtris Specialty Chemicals Ltd.

IW1 Interwet 33 Surfactant (Independence, Ohio)

Huber

Engineered

CaCO3 k3A Calcium Carbonate Materials Co.

(Atlanta,

Georgia)

Sartomer

Trimethylolpropane Company

TMPTA SR351 triacrylate (Exton,

Pennsylvania)

Imerys Fused

P600 grade BFRPL

P600 Minerals

P600 BFRPL aluminum oxide

Mineral (Niagara Falls, mineral

New York) Preparations:

Calendering

A 12-inch wide mesh backing was calendered using a 2-roll vertical stack. The rolls were smooth stainless steel. The calender conditions are shown in Table 2. The mesh backing was fed into the calender with the loop facing the lower roll. The side where the abrasive will later be coated onto was facing the upper roll. The upper roll had a temperature of 400 degrees Fahrenheit and the lower roll had a temperature of 200 degrees Fahrenheit. The pressure between the upper and lower rolls was set to 600 pounds per linear inch and the mesh was advanced at a line speed.

Table 2 - Calendering conditions

Sample Mesh Line Speed (feet/minute)

CalMesh A Mesh A 20

CalMesh B Mesh B 10

CalMesh C Mesh C 20

CalMesh D Mesh D 10

Abrasive Articles

Make Resin: A gellable make resin was prepared by dissolving 54 parts by weight ECI, 0.4 parts by weight IW1, and 11 parts by weight of TMPTA. To this solution mixture was added 34 parts by weight of CACO3; and 2.27 parts by weight deionized water.

Size Resin: The size resin was prepared by dissolving 88 parts by weight ECI and 12 parts by weight water.

Non-Pattem coat on net mesh:

A net mesh abrasive was achieved by applying make resin onto the top fibers of the mesh using a roll coater. The roll coater, having a steel top roller and a 90 Shore A durometer rubber bottom roller immersed in the make coat, was obtained from Eagle Tool, Inc., Minneapolis, MN. The amount of make coat transferred to the mesh was adjusted until only the top fibers of the mesh were coated or approximately 40 grams per square meter. The make coated mesh was gelled by irradiation with an ultraviolet (UV) lamp, type “D” bulb, from Fusion Systems Inc., at 15 m/min and 200 Watts/inch. 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 165 deg. Fahrenheit (F) for 45 minutes and then 240 deg. F for 20 minutes.

After curing, the size resin was coated using a roll coater. The roll coater, having a steel top roller and a 90 Shore A durometer rubber bottom roller immersed in the size coat. 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 at 230 deg. F for 2 hours.

Pattern coat on film net mesh:

A pattern coated net mesh abrasive was achieved by applying make resin onto a film coated mesh backing through a patterned stencil. The extruded film laminated mesh was made similar to what is described in PCT Publication WO 2021/116882 to 3M, filed December 9, 2019. The pattern stencil printing was done as described in U.S. Patent 9393673B2 using the pattern shown in FIG. 8. After the make was applied the make coated mesh was gelled by irradiation with an ultraviolet (UV) lamp, type “D” bulb, from Fusion Systems Inc., at 15 m/min and 200 Watts/inch. 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 165 deg. F for 45 minutes and then 240 deg. F for 20 minutes.

After curing, the size resin was coated using a roll coater. The roll coater had a steel top roller and a 90 Shore A durometer rubber bottom roller immersed in the size coat. 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 at 23 OF. The pattern coat was prepared with 50% of the available surface area. The preparations are shown in Table 3. Table 3 - Examples

Example Coat method Mesh backing

EXI Pattern CalMesh B

EX2 Pattern CalMesh C

EX3 Direct CalMesh B

EX4 Direct CalMesh D

CE1 Pattern Mesh B

CE2 Pattern Mesh C

CE3 Direct Mesh B

CE4 Direct Mesh D

Test Methods

Coefficient of Friction (COF) Test Method

Coefficient of Friction measurements were carried out following ASTM DI 894- 14. In a controlled temperature humidity room (72°F, 50% RH), an 8”xl0” stainless steel panel was secured on top of a IMASS SP2000 available from IMASS, Accord, Massachusetts using the appropriate panel clips included with the IMASS. An 8”x 8” sample of mesh backing was cut and secured to the steel plate using 233+ masking tape available from 3M company. The orientation of the mesh on the steel plate was noted as being machine direction or perpendicular to machine direction. A friction sled with tether available from IMASS, Part # SP-101038, was modified by wrapping a pre-cut 2.5 in (6.4 cm) x 8 in (20.3 cm) mesh backing sample around the sled. The orientation of the mesh (machine or perpendicular) was kept consistent to the mesh applied to the steel plate. A small slit was cut into the wipe to allow the tether to be exposed. The mesh backing wrapped around the sled was further secured with 233+ masking tape available from 3M Company. The modified friction sled was then attached to the IMASS SP2000 by the provided tether and the sled was placed onto the steel panel that contains the mesh backing with the tape side up. The IMASS SP2000 settings were adjusted in the setup menu to the following: Sled Weight: 200g; Initial Delay: 2 seconds; Averaging Time: 5 seconds; Units: In/Min; Testing Speed: 6 in/min. After the instrument was set up, samples were tested 3 times (15 seconds total) and the kinetic potential (KP) results were averaged. Measurements were obtained in the machine-direction (warp was parallel to direction being pulled) and the cross-direction (warp is perpendicular to direction being pulled). The results are in Table 4.

Surface Area Test Method

Surface area calculations were calculated using a Keyence VHX 5000 digital microscope (Version 1.6.1.0) (Keyence Corporation, Osaka, Japan). Mesh samples were laid flat on the microscope stage and the zoom was set to 5 Ox. Once the top surface fiber was in focus the measure tool was selected. The software used was the Keyence System version 1.04. In the measure menu, the auto area measurement was chosen. For white samples, such as Sample D, the brightness tool was selected. For colored samples, such as Sample C, the color was selected. The color or brightness threshold was manually adjusted (between 24 and 41) until the majority of the fiber was highlighted and the open area was blacked out. Once the threshold was recorded the sample was measured and the % area was calculated. The results are in Table 5.

Raised Portion Topological Profile Method

The topological profile was determined using a Keyence VKX1100 confocal 3D measuring confocal microscope (Keyence Corporation, Osaka, Japan). A 4-inch by 4-inch swath of the combination was placed on the sample tray and a 1 OX magnification, with ring and axial lighting was used for the evaluation. The resulting image was analyzed using VK Series Analyzer Software (Keyence Corporation, Osaka, Japan). An associated height differential was determined by taking the elevation of the raised portion and the elevation of adjacent portions. The results are described in FIG. 7. For example, the calendering for Mesh B to CalMesh B results in a 70 percent decrease in the height differential (or at least a 40 micrometer decrease) and the calendering from Mesh C to CalMesh C results in a 74 percent decrease in the height differential (or at least a 60 micrometer decrease).

Abrading Test Method

Abrasive performance of the abrasive articles made were evaluated on 18-inch by 24- inch black painted cold roll steel test panels having a RK8211 clearcoat, obtained from ACT laboratories, Inc., Hillsdale, Michigan. For testing purposes, the abrasive discs in 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.

Sanding was performed along the 18 inch width direction moving the sander in a back-and-forth motion at a speed of approximately 1 foot per second. Stroke length was approximately 16 inches and the downward force on the sander was approximately 201bs. 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 was 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. The results are shown in Table 6.

Results

Table 4 - Coefficient of Friction

Mesh MD/CD Max KP Avg. KP

Mesh B MD 0.51 0.3

CalMesh B MD 0.36 0.28

Mesh B CD 0.92 0.66

CalMesh B CD 0.8 0.63

Table 5 - Open area

Mesh % Open Area (avg.) % Decrease in Open Area from Calendering

CalMesh B 42 20.7

Mesh B 53

CalMesh C 31.7 31.5

Mesh C 46.3

Table 6 - Abrading Test

Example Total cut (g)

EXI 0.70

CE1 0.26

EX2 0.70

CE2 0.46

EX3 0.67

CE3 0.51

EX4 0.42

CE4 0.30

As shown from the results in Table 6, Examples of the present disclosure allow for at least a 40% increase of total cut over the comparative non-calendered mesh backing.

DEFINITIONS "Bobble" refers to a localized set of stiches forming a raised bump. A nupp can refer to a type of bobble.

"Calender" refers to a series of hard pressure rollers used to finish or smooth a sheet of material, or the verb of calendering.

"Calendering" refers to a finishing process used to smooth, coat, or thin a material. In at least one embodiment, the mesh backing can be passed between calendered at elevated temperatures and pressures.

"Ends per inch" refers to the number of warp threads in one inch of woven fabric.

"Knitted fabric" refers to a textile that results from knitting, the process of interlooping of yams or intermeshing of loops. Knitting can create multiple interlocking loops of yam from a continuous yam. Knitted fabric can also refer to an article formed from a continuous first yarn (which can also refer to lengths of yarn tied end to end) and placing a second yam through the first yam.

"Layer" refers to zone having a thickness of material that covers at least a portion of a surface. Layer can refer to continuous or discrete, discontinuous sections of material. If discontinuous, then the layer can have a similar thickness of material throughout the layer.

"Mesh backing" refers to knitted fabric, woven fabric, or an extmded plastic mesh that has visible openings sufficient to allow swarf to pass thru.

"Pick" refers to a region formed from the intersection of a weft and a warp yam in a woven fabric.

"Picks per inch" refers to the number of weft yam in one inch of woven fabric.

"Stitch" refers to a link, loop, or knot resulting from a single pass of a needle.

"Warp" refers to yams in woven or knitted fabric that run lengthwise.

"Warp knitted" refers to process of knitting involving a number of threads that are bound together by formation of stiches and in which the loops made from each warp thread are formed mostly along the length of the fabric.

"Warp knitted fabric" refers to a fabric formed by weaving.

"Weft" refers to yarns that are filled in the woven fabric that mn perpendicular to the warp yarns.

"Woven fabric" refers to a fabric formed from interlacing two sets of yarns at right angles to each other. The weaving may be performed by using a loom.

"Yam" refers to one or more individual elements such as filaments, bundles of fibers, wires, or cords which follow the same path through the fabric.