Latterally-stretched netting bearing abrasive particles, and method for making

Patent metadata

Field	Value
Publication number	US-2016354898-A1
Application number	US-201615165848-A
Country	US
Kind code	A1
Filing date	May 26, 2016
Priority date	Jun 2, 2015
Publication date	Dec 8, 2016
Grant date	—

Abstract

A laterally-stretched netting comprising a patterned abrasive layer on a first major surface thereof, and methods of making.

First claim

What is claimed is:

1 . A method of making a laterally-stretched netting comprising a patterned abrasive layer on a first major surface thereof, the method comprising the steps of:
providing a netting comprising a lateral width and comprising a first set of polymer strands and a second set of polymer strands, polymer strands of the first set being bonded to polymer strands of the second set at bond regions, and the first and second sets of strands comprising first surfaces that collectively define a first major surface of the netting; coating a make coat layer onto the first major surface of the netting so that at least some first surfaces of strands of the first set of strands, and some first surfaces of strands of the second set of strands, are make-coated strands; depositing abrasive particles onto at least some of the make-coated first surfaces of strands that define the first major surface of the netting, in a pre-determined pattern; laterally stretching the netting by a stretching factor of at least about 25%; and, hardening the make coat layer; whereby at least a majority of the abrasive particles are each singly bonded to a strand of the laterally-stretched netting.

2 . The method of claim 1 wherein the method includes partially hardening the make coat layer before laterally stretching the netting.

3 . The method of claim 1 wherein the abrasive particles are shaped abrasive particles and wherein the depositing of the shaped abrasive particles is performed so that the particles are deposited onto the make-coated strands in a predetermined orientation.

4 . The method of claim 3 wherein at least some of the shaped abrasive particles are at least generally shaped as pyramids with a tip and with a base opposing the tip, and wherein the shaped abrasive particles are deposited onto the make-coated first surfaces of the strands so that the base of the pyramid contacts the make-coated strands.

5 . The method of claim 1 wherein the netting is laterally stretched by a stretching factor of at least about 100%.

6 . The method of claim 1 wherein the netting is in the form of first and second polymer strands that are periodically joined together at bond regions throughout the netting, but do not substantially cross over each other.

7 . The method of claim 6 wherein the polymer strands of the first set and the polymer strands of the second set are at least substantially coplanar with each other and wherein the netting does not comprise any polymer strands other than those of the first and second sets.

8 . The method of claim 1 wherein the netting, prior to being laterally stretched, exhibits a percent open area of at most about 30%.

9 . The method of claim 1 wherein the netting, prior to being laterally stretched, exhibits a percent open area of at most about 20%.

10 . The method of claim 1 wherein the netting, after being laterally stretched, exhibits a percent open area of at least about 60%.

11 . The method of claim 1 wherein the netting, after being laterally stretched, exhibits a percent open area of at least about 90%.

12 . The method of claim 1 wherein the depositing abrasive particles onto at least some of the first surfaces of the make-coated strands that define the first major surface of the netting, in a pre-determined pattern, is performed by the use of one or more apertured screens, each of which apertures is configured to position an abrasive particle in a specific z-directional orientation, and which apertures are spaced and patterned in a predetermined pattern.

13 . The method of claim 1 wherein the depositing abrasive particles onto at least some of the first surfaces of the make-coated strands that define the first major surface of the netting, in a pre-determined pattern, is performed by the use of a production tool having a dispensing surface with a plurality of cavities, wherein abrasive particles are dispensed from an abrasive particle feeder onto the dispensing surface and into the plurality of cavities, and wherein the abrasive particles are transferred from the plurality of cavities to the first surfaces of the make-coated strands that define the first major surface of the netting.

14 . The method of claim 13 wherein the abrasive particles are sized so that each abrasive particle fits completely into a cavity of the plurality of cavities.

15 . The method of claim 13 wherein at least some of the cavities are elongated cavities that exhibit a longitudinal axis, wherein at least some of the abrasive particles are elongated particles that exhibit a longitudinal axis, and wherein the abrasive particles are dispensed onto the dispensing surface and into the plurality of cavities, so that at least some of the elongated particles are disposed in the elongated cavities such that the longitudinal axis of the particle is at least substantially parallel to the longitudinal axis of the elongated cavity.

16 . The method of claim 1 further comprising the step of attaching the laterally-stretched netting bearing a patterned abrasive layer thereon, to a nonwoven fibrous support layer.

17 . The method of claim 1 wherein the method comprises attaching multiple laterally-stretched nettings, each bearing a patterned abrasive layer thereon, to each other to form a multilayer article.

18 . A laterally-stretched netting comprising a patterned abrasive layer on a first major surface thereof, comprising:
a laterally-stretched netting comprising a lateral width and comprising a first set of polymer strands and a second set of polymer strands, polymer strands of the first set being bonded to polymer strands of the second set at bond regions, and the first and second sets of strands each comprising first surfaces that collectively define a first major surface of the netting; a make coat layer on at least portions of the first major surface of at least some strands of the first set of strands, and on at least portions of the first major surface of at least some strands of the second set of strands; a plurality of abrasive particles at least a majority of which are singly bonded, by way of the make coat layer, to a first surface of a strand of the first or second set of polymer strands.

19 . The laterally-stretched netting of claim 18 wherein the plurality of abrasive particles are present in a predetermined pattern.

20 . The laterally-stretched netting of claim 18 wherein at least a majority of the abrasive particles are present in a predetermined orientation.

21 . The laterally-stretched netting of claim 20 wherein the abrasive particles are pyramidal shaped particles and wherein at least a majority of the abrasive particles are present in a predetermined orientation in which a tip of the particle faces outward, away from a major plane established by the first major surface of the laterally-stretched netting.

22 . The laterally-stretched netting of claim 18 wherein the laterally-stretched netting exhibits a percent open area of at least about 80%.

23 . The laterally-stretched netting of claim 18 wherein the laterally-stretched netting exhibits a percent open area of at least about 90%.

24 . The laterally-stretched netting of claim 18 wherein the netting is in the form of first and second polymer strands that are periodically joined together at bond regions throughout the array, but do not substantially cross over each other.

25 . The laterally-stretched netting

Assignees

• 3M Innovative Properties Co

Inventors

• Nienaber Aaron K
• Ausen Ronald W
• Brandner John M
• Nelson Thomas J
• Sanocki Stephen M

Classifications

• B24D3/002 Primary

  Flexible supporting members, e.g. paper, woven, plastic materials · CPC title

• B24D18/0072

  using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing · CPC title