Coated abrasive article and method of making the same

Abstract

A structured abrasive article is contacted by a laser beam to create microporous surface regions over a portion of the abrading surface to make a coated abrasive article that includes a backing and an abrasive layer comprising abrasive composites secured to the backing.

1 - 14 . (canceled) 
     
     
         15 . A method of making a coated abrasive article, the method comprising:
 providing a structured abrasive article comprising:
 a backing having first and second opposed major surfaces; and 
 an abrasive layer secured to the first major surface of the backing, the abrasive layer comprising abrasive composites secured to the first major surface of the backing, the abrasive layer having an abrading surface opposite the second major surface of the backing, wherein the abrasive composites comprise abrasive particles retained in a binder matrix, and wherein the abrading surface has a first projected area on the first major surface of the backing; and 
   contacting a portion of the abrading surface with a laser beam to provide at least one microporous surface region in the abrading surface, wherein a majority of the microporous surface region comprises the binder matrix, wherein the at least one microporous surface region has a surface roughness greater than in portions of the abrading surface immediately adjacent to the at least one microporous surface region, wherein a projection of the at least one microporous surface region onto the first major surface in a direction perpendicular to the first major surface has a second projected area on the first major surface of the backing, and wherein the ratio of the second projected area to the first projected area is from 0.15 to 0.90, inclusive.   
     
     
         16 . The method of  claim 15 , wherein the ratio of the second projected area to the first projected area is from 0.25 to 0.80, inclusive. 
     
     
         17 . The method of  claim 15 , wherein the ratio of the second projected area to the first projected area is from 0.35 to 0.70, inclusive. 
     
     
         18 . The method of  claim 15 , wherein the at least one microporous surface region is disposed uniformly over the abrading surface. 
     
     
         19 . The method of  claim 15 , wherein the at least one microporous surface region forms a grid pattern extending uniformly over the abrading surface. 
     
     
         20 . The method of  claim 15 , wherein at least a portion of the abrasive composites comprise pyramids. 
     
     
         21 . The method of  claim 15 , wherein the coated abrasive article comprises a coated abrasive disc or a coated abrasive belt. 
     
     
         22 . A coated abrasive article comprising:
 a backing having first and second opposed major surfaces;   an abrasive layer secured to the first major surface of the backing, the abrasive layer comprising abrasive composites secured to the first major surface of the backing, the abrasive layer having an abrading surface opposite the second major surface of the backing, wherein projection of the abrading surface onto the first major surface in a direction perpendicular to the first major surface corresponds to a first projected area on the first major surface of the backing, wherein the abrasive composites comprise abrasive particles retained in a binder matrix; and   wherein the abrading surface comprises at least one microporous surface region wherein a majority of the microporous surface region comprises the binder matrix, wherein the at least one microporous surface region has a surface roughness greater than in portions of the abrading surface immediately adjacent to the at least one microporous surface region, wherein a projection of the at least one microporous surface region onto the first major surface in a direction perpendicular to the first major surface has a second projected area on the first major surface of the backing, and wherein the ratio of the second projected area to the first projected area is from 0.15 to 0.90, inclusive.   
     
     
         23 . The coated abrasive article of  claim 22 , wherein the ratio of the second projected area to the first projected area is from 0.25 to 0.80, inclusive. 
     
     
         24 . The coated abrasive article of  claim 22 , wherein the ratio of the second projected area to the first projected area is from 0.35 to 0.70, inclusive. 
     
     
         25 . The coated abrasive article of  claim 22 , wherein the at least one microporous surface region is disposed uniformly over the abrading surface. 
     
     
         26 . The coated abrasive article of  claim 22 , wherein the at least one microporous surface region forms a grid pattern extending uniformly over the abrading surface. 
     
     
         27 . The coated abrasive article of  claim 22 , wherein at least a portion of the abrasive composites comprise pyramids. 
     
     
         28 . The coated abrasive article of  claim 22 , wherein the coated abrasive article comprises a coated abrasive disc or a coated abrasive belt.