Abrasive article

Abstract

An abrasive article having a backing layer having a first major surface opposing a second major surface and a plurality of apertures extending from the first major surface to the second major surface. A plurality of abrasive particles having a first end with a smaller dimension than a second end and at least some of the plurality of abrasive particles located in at least some of the plurality of apertures such that the first end of the abrasive particle passes through an individual aperture and extends above the second major surface and the second end of the abrasive particle will not pass through the individual aperture. A binder coating applied to the plurality of abrasive particles retaining them in the backing layer.

1 . An abrasive article comprising:
 a backing layer having a first major surface opposing a second major surface and a plurality of apertures extending from the first major surface to the second major surface;   a plurality of abrasive particles having a first end with a smaller dimension than a second end;   at least some of the plurality of abrasive particles located in at least some of the plurality of apertures such that the first end of the abrasive particle passes through an individual aperture and extends above the second major surface and the second end of the abrasive particle will not pass through the individual aperture; and   a binder coating applied to the plurality of abrasive particles retaining them in the backing layer.   
     
     
         2 . The abrasive article of  claim 1  wherein for a majority of the plurality of apertures only one abrasive particle resides in an individual aperture. 
     
     
         3 . The abrasive article of  claim 1  wherein more than one individual abrasive particle resides in an individual aperture. 
     
     
         4 . The abrasive article of  claim 1  wherein the plurality of abrasive particles comprise formed abrasive particles. 
     
     
         5 . The abrasive article of  claim 4  wherein the plurality of abrasive particles compromise a triangular shape and a vertex of the triangle comprises the first end and extends above the second major surface and a base of the triangle comprises the second end and extends above the first major surface. 
     
     
         6 . The abrasive article of  claim 5  where a width dimension of the base is at least 10% greater than a width dimension of the apertures and the width dimension of the base is no more than 40% greater than the width dimension of the apertures. 
     
     
         7 . The abrasive article of  claim 1  wherein the plurality of apertures comprise a shape selected from the group consisting of rectangular, oval, square, circle, and trapezoid. 
     
     
         8 . The abrasive article of  claim 1  wherein the plurality of apertures are arranged in a pattern selected form the group consisting of spiral, linear, double parquet, and sawtooth. 
     
     
         9 . The abrasive article of  claim 1  wherein the backing comprises a thickness of between 10 to 40 mils. 
     
     
         10 . The abrasive article of  claim 1  wherein the plurality of particles comprise triangular particles having a base dimension of X in width and the plurality of apertures comprise a rectangular shape having a width dimension of 0.6X to 0.90X. 
     
     
         11 . The abrasive article of  claim 1  wherein the binder is applied to the second ends of the abrasive particles and the second major surface. 
     
     
         12 . A method of making an abrasive article comprising:
 forming a backing layer having a first major surface opposing a second major surface and a plurality of apertures extending from the first major surface to the second major surface;   providing a plurality of abrasive particles having a first end with a smaller dimension than a second end;   positioning at least some of the plurality of abrasive particles in at least some of the plurality of apertures such that the first end of the abrasive particle passes through an individual aperture and extends above the second major surface and the second end of the abrasive particle will not pass through the individual aperture; and   applying a binder coating applied to the plurality of abrasive particles retaining them in the backing layer.   
     
     
         13 . The method of  claim 12  wherein the backing layer does not have a binder coating applied to it prior to applying the abrasive particles. 
     
     
         14 . The method of  claim 13  wherein the binder coating is applied to the second ends of the abrasive particles and the first major surface. 
     
     
         15 . The method of  claim 14  further comprising the step of bringing the first ends of the abrasive particles into contact with a workpiece and inducing relative motion between the workpiece and the first ends to abrade the workpiece.