Abrasive article having a dross ridge and method of forming same

Abstract

An abrasive article having at least one edge, and a dross ridge extending from at least a portion of the edge. The edge can define the periphery of the abrasive article or an aperture formed in a portion the abrasive article. The dross ridge can have a width dimension of at least 101 μm, and not greater than about 500 μm. The dross ridge can also have height dimension of at least about 1 μm, and not greater than about 50 μm. The edge and the dross ridge can be formed by a laser.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a first surface having an edge; and   a dross ridge formed on the first surface, the dross ridge extending from at least a portion of the edge by an average width of at least about 101 μm and not greater than about 500 μm.   
     
     
         2 . The abrasive article of  claim 1 , wherein the edge defines an aperture. 
     
     
         3 . The abrasive article of  claim 1 , wherein the average width of the dross ridge is defined as the average distance between the edge and an outer boundary of the dross ridge measured in a direction in which the dross ridge extends perpendicularly from the edge. 
     
     
         4 . The abrasive article of  claim 1 , wherein the dross ridge comprises a recast material. 
     
     
         5 . The abrasive article of  claim 1 , wherein the dross ridge further includes a height defined by the average highest point on the dross ridge measured from the first surface as viewed from a cross section of the dross ridge defined by a direction in which the dross ridge extends perpendicularly from the edge. 
     
     
         6 . The abrasive article of  claim 5 , wherein the height of the dross ridge is not greater than about 50 μm and is at least about 1 μm. 
     
     
         7 . The abrasive article of  claim 5 , wherein the dross ridge includes a ratio of height (h dr ) to dross ridge width (w dr ) of not greater than about 0.495 according to the equation h dr /w dr . 
     
     
         8 . The abrasive article of  claim 1 , wherein the first surface comprises an abrasive layer that is secured to a backing, and wherein the abrasive layer includes abrasive particles. 
     
     
         9 . The abrasive article of  claim 8 , wherein the abrasive particles have a D50 of not greater than about 30 μm. 
     
     
         10 . The abrasive article of  claim 8 , wherein the abrasive layer comprises a make coat, a size coat, a supersize coat, or a combination thereof. 
     
     
         11 . A method of forming an abrasive article, comprising:
 providing an abrasive article having a first surface and a second surface spaced apart from the first surface;   forming an edge on the first surface; and   forming a dross ridge on the first surface, the dross ridge extending from at least a portion of the edge by an average width of at least about 101 μm and not greater than about 500 μm.   
     
     
         12 . The method of  claim 11 , wherein forming the dross ridge includes forming a dross ridge with a laser. 
     
     
         13 . The method of  claim 12 , wherein the laser has a maximum average power of at least about 1000 watts. 
     
     
         14 . The method of  claim 12 , wherein forming the dross ridge includes directing the laser to impact the second surface before the first surface. 
     
     
         15 . The method of  claim 11 , wherein forming the dross ridge on the first surface of the abrasive article includes forming an aperture that extends from the second surface of the abrasive article to the first surface of the abrasive article.