Method of forming structured abrasive article

1. A method of forming a structured abrasive article, the method comprising:

coating a backing with a binder formulation comprising a solution-formed nanocomposite, the solution-formed nanocomposite comprising a polymer precursor and a particulate filler having an average particle size of less than 100 nm, the solution-formed nanocomposite formed by mixing a sol including the particulate filler with the polymer precursor, the binder formulation including greater than 5 wt % of the particulate filler;

partially curing the binder formulation by exposing the binder formulation to actinic radiation; and

forming a pattern in the partially cured binder formulation.

2. The method of claim 1 , further comprising fully curing the binder formulation after forming the pattern.

3. The method of claim 2 , wherein fully curing the binder formulation after forming the pattern includes exposing the binder formulation to actinic radiation.

4. The method of claim 2 , wherein fully curing the binder formulation after forming the pattern includes thermally curing.

5. The method of claim 1 , further comprising applying abrasive grains over the binder formulation.

6. The method of claim 5 , wherein applying the abrasive grains comprises applying the abrasive grains prior to partially curing the binder formulation.

7. The method of claim 1 , wherein partially curing the binder formulation includes partially curing the binder formulation to a Viscosity Index of at least about 1.1.

8. The method of claim 1 , further comprising mixing the binder formulation with abrasive grains to form an abrasive slurry.

9. The method of claim 1 , wherein forming the pattern includes forming the pattern using a heated patterning tool.

10. A method of forming a structured abrasive article, the method comprising:

coating a backing with an abrasive slurry comprising binder formulation and abrasive grains, wherein the binder formulation comprises a solution-formed nanocomposite, the solution-formed nanocomposite comprising a polymer precursor and a particulate filler having an average particle size of less than 100 nm, the solution-formed nanocomposite formed by mixing a sol including the particulate filler with the polymer precursor, the binder formulation including greater than 5 wt % of the particulate filler;

partially curing the abrasive slurry by exposing the abrasive slurry to actinic radiation; and

forming a pattern in the partially cured abrasive slurry.

11. The method of claim 10 , further comprising fully curing the abrasive slurry after forming the pattern.

12. The method of claim 10 , wherein partially curing the abrasive slurry includes partially curing the binder formulation to a Viscosity Index of at least about 1.1.

13. The method of claim 10 , further comprising mixing the binder formulation with the abrasive grains to form the abrasive slurry.

14. A method of forming a structured abrasive article, the method comprising:

partially curing a binder formulation to a Viscosity Index of at least about 1.1 by exposing the binder formulation to actinic radiation, wherein the binder formulation comprises a solution-formed nanocomposite, the solution-formed nanocomposite comprising a polymer precursor and a particulate filler having an average particle size of less than 100 nm, the solution-formed nanocomposite formed by mixing a sol including the particulate filler with the polymer precursor, the binder formulation including greater than 5 wt % of the particulate filler;

forming a pattern of structures in the partially cured binder formulation; and

further curing the partially cured binder formulation.

15. The method of claim 14 , further comprising coating a backing with the binder formulation prior to partially curing the binder formulation.

16. The method of claim 14 , wherein the partially cured binder formulation has a Viscosity Index of at least about 5.0.

17. The method of claim 14 , further comprising applying abrasive grains over the binder formulation.