Flexible abrasive product and method of making and using the same

Abstract

The present invention provides a flexible abrasive product comprised of an open cell foam backing, a foraminous barrier coating and a shaped foraminous abrasive coating. The flexible abrasive article of the invention is made by applying a curable barrier coating over an open cell foam backing, curing the curable barrier coating to provide a foraminous barrier coating having openings therethrough corresponding to openings in the open cell foam, applying a coating composition comprising a curable binder and abrasive particles over the foraminous barrier coating, imparting a textured surface to the coating composition with a production tool which has a textured surface which is the inverse of the textured surface of the abrasive coating and to which production tool textured surface any coating composition coated over an opening of the first major surface may adhere, at least partially curing the binder, and separating the production tool from the textured surface to provide the shaped foraminous abrasive coating.

1 .- 17 . (Canceled)  
   
   
       18 . A flexible abrasive article comprising: 
 a. foam backing having a minimum thickness of at least 2 mm, a first major surface and an opposite second major surface; and    b. a shaped abrasive coating having recessed portions and raised portions comprised of abrasive particles in a binder over said first major surface of the foam backing.    
   
   
       19 . The flexible abrasive article of  claim 18  wherein said foam backing is an open cell foam backing.  
   
   
       20 . A method of making an abrasive article, said method comprising the following steps: 
 a. providing a foam backing having a minimum thickness of at least 2 mm, a first major surface, and an opposite second major surface;    b. adhering to the second major surface one part of a two part attachment sheet material to provide dimensional stability to foam backing;    c. applying a shaped coating composition comprising a curable binder and abrasive particles over said first major surface of foam backing, said coating composition being curable to provide a shaped abrasive coating; and    d. curing the curable binder.    
   
   
       21 . The flexible abrasive product of  claim 18  wherein the foam backing has a contoured surface including a regular array of projecting portions and recessed portions.