Abrasive article and methods of making the same

Abstract

An abrasive article and methods of making the same are disclosed. The abrasive article includes a backing and an array of features on the backing. Each feature includes a base and a body. The body includes a face having an undercut. In one embodiment, the feature also includes a planar top portion having abrasive particles disposed thereon. In another embodiment, the feature also includes a radiused portion on the undercut sidewall adjacent the base.

1 . An abrasive article comprising: 
 a backing; and    a plurality of features, said features further comprising a binder and abrasive particles, wherein said features have a base and at least three sides, the angle between said base and one of said sides forming a positive rake angle.    
     
     
         2 . The abrasive article of  claim 1  wherein at one of said abrasive features further includes a planar top portion that is angled with respect to said base.  
     
     
         3 . The abrasive article of  claim 2 , further including abrasive particles on the planar top portion of said abrasive features.  
     
     
         4 . The article of  claim 1 , wherein the body includes a region or point located most distally from the base, and further wherein the region or point projects outside the base perimeter.  
     
     
         5 . The abrasive article of  claim 4  wherein at least one of said abrasive features further includes a top planar section that is angled with respect to said base.  
     
     
         6 . A method of making an abrasive article comprising: 
 providing a tool including a pattern for forming abrasives features;    placing abrasive particles in the tool;    filling the tool with a slurry;    contacting the slurry with a backing; and    curing the slurry to form abrasive features including a top portion bonded to said abrasive particles and a bottom portion bonded to said backing.    
     
     
         7 . The method of  claim 6 , wherein providing a tool includes providing a tool for forming abrasives features including a planar top.  
     
     
         8 . The method of  claim 7 , wherein the planar top is angled with respect to a reference plane defined by the backing.  
     
     
         9 . The method of  claim 7 , wherein the abrasive particles are aluminum oxide.  
     
     
         10 . An abrasive article comprising: 
 a backing; and    a plurality of abrasive features on the backing, each of the abrasive features including a base and a body, wherein the body is defined by four surfaces, and wherein at least one of the surfaces includes an undercut portion.    
     
     
         11 . The article of  claim 10 , further including a planar surface opposite the base.  
     
     
         12 . The article of  claim 11 , further including abrasive particles disposed on the planar surface.  
     
     
         13 . The article of  claim 12 , wherein the planar surface is angled with respect to the base.  
     
     
         14 . The article of  claim 12 , wherein the undercut portion includes a radiused section adjacent the base.  
     
     
         15 . The article of  claim 10 , wherein the undercut portion includes a radiused section adjacent the base.  
     
     
         16 . The abrasive article of  claim 10 , wherein the plurality of features are arranged in an array wherein each undercut potion is oriented in the same direction.  
     
     
         17 . The abrasive article of  claim 16 , wherein the array is oriented at a bias on the abrasive article.  
     
     
         18 . A feature for an abrasive article comprising: 
 a base and a body, the body including four sidewalls, wherein at least one sidewall forms a surface having a positive rake angle.    
     
     
         19 . The feature of  claim 18 , further including a planar top section disposed distally from the base.  
     
     
         20 . The feature of  claim 19 , wherein the planar top section is oriented substantially parallel to the base.  
     
     
         21 . The feature of  claim 19 , wherein the planar top section is oriented at an angle of more than about 2 degrees with respect to the base, and further wherein the planar top section slopes away from surface having a negative rake angle.  
     
     
         22 . The feature of  claim 19 , further including abrasive particles disposed on the planar top section.  
     
     
         23 . The feature of  claim 18 , wherein the surface includes a radiused portion adjacent the base.  
     
     
         24 . The feature of  claim 22 , wherein the surface includes a radiused portion adjacent the base.  
     
     
         25 . A tool for making any of the abrasive articles in claims  1 - 17 .  
     
     
         26 . An belt for abrading material comprising: 
 a backing defining a belt shape; and    a plurality of abrasive composites on the backing, each of the abrasive composites including a base and a body, wherein the body is defined by four surfaces, and wherein at least one of the surfaces includes an undercut portion.    
     
     
         27 . The belt of  claim 26 , further including a planar surface opposite the base.  
     
     
         28 . The belt of  claim 27 , further including abrasive particles disposed on the planar surface.  
     
     
         29 . The belt of  claim 28 , wherein the planar surface is angled with respect to the base.  
     
     
         30 . The belt of  claim 28 , wherein the undercut portion includes a radiused section adjacent the base.  
     
     
         31 . The belt of  claim 26 , wherein the undercut portion includes a radiused section adjacent the base.  
     
     
         32 . The belt of  claim 26 , wherein the plurality of composites are arranged in an array wherein each undercut potion is oriented in the same direction.  
     
     
         33 . The belt of  claim 32 , wherein the array is oriented at a bias on the abrasive article.  
     
     
         34 . A method of abrading a wooden workpiece, the method comprising: 
 contacting an abrasive article to the workpiece, wherein the abrasive article includes: 
 a backing;  
 a plurality of abrasive composites on the backing, each of the abrasive composites including a base and a body, wherein the body is defined by four surfaces, and wherein at least one of the surfaces includes an undercut portion, and  
   wherein a section of the undercut portion engages the workpiece before any other surface of the body.    
     
     
         35 . The method of  claim 34 , wherein said contacting an abrasive article further includes contacting the abrasive article including a planar top section, and wherein abrasive particles are disposed on the top section.  
     
     
         36 . The method of  claim 34 , wherein said contacting an abrasive article further includes contacting the abrasive article including a radiused portion adjacent the base on the undercut portion.  
     
     
         37 . The method of  claim 36 , further including removing swarf via the radiused portion.  
     
     
         38 . The method of  claim 34 , wherein the backing is a belt.