Porous abrasive article

Abstract

An abrasive article comprising an attachment layer and an abrasive layer. The attachment layer comprises a porous backing having a first major surface, an opposed second major surface, and a first plurality of voids extending from the first major surface to the second major surface. The abrasive layer has a third major surface and an opposed fourth major surface and comprises a cured composition, abrasive particles at least partially embedded in the cured composition, and a second plurality of voids extending from the third major surface to the fourth major surface. The first major surface of the attachment layer is adjacent the third major surface of the abrasive layer, and the pattern of the second plurality of voids is independent of the pattern of the first plurality of voids.

What is claimed is: 
     
         1 . A method of making an abrasive article, comprising:
 providing an attachment layer comprising a porous backing layer having a first major surface, an opposed second major surface and a first plurality of voids forming a first regular pattern and extending from the first major surface to the second major surface; and one part of a two-part interconnecting attachment mechanism layer adjacent the second major surface;   disposing a curable abrasive layer, having a third major surface and an opposed fourth major surface, on the attachment layer, wherein the first major surface of the attachment layer is adjacent the third major surface of the curable abrasive layer,   wherein the curable abrasive layer comprises a curable composition; abrasive particles at least partially embedded in the curable composition; and a second plurality of voids, absent of the curable composition, extending from the third major surface to the fourth major surface and forming a second regular pattern, the second pattern being independent of the first pattern; and   curing the curable composition to form a cured abrasive layer.   
     
     
         2 . The method of  claim 1 , wherein the attachment layer includes one part of a two-part interconnecting attachment mechanism integral to the porous backing layer. 
     
     
         3 . The method of  claim 1 , wherein the attachment layer includes one part of a two-part interconnecting attachment mechanism layer adjacent the second major surface. 
     
     
         4 . The method of  claim 1 , wherein the one part of a two-part interconnecting attachment mechanism includes at least one of a hook and a loop. 
     
     
         5 . The method of  claim 1 , wherein the releasable layer is a release liner. 
     
     
         6 . The method of  claim 1 , wherein the abrasive article further comprises at least one of a size coat and a supersize coat located adjacent the fourth major surface. 
     
     
         7 . A method of making an abrasive article, comprising:
 providing an attachment layer comprising a porous backing layer having a first major surface, an opposed second major surface and a first plurality of voids forming a first regular pattern and extending from the first major surface to the second major surface;   disposing a curable abrasive layer, having a third major surface and an opposed fourth major surface, on the attachment layer, wherein the first major surface of the attachment layer is adjacent the third major surface of the curable abrasive layer,   wherein the curable abrasive layer comprises a curable composition, abrasive particles at least partially embedded in the curable composition and a second plurality of voids, absent of the curable composition, extending from the third major surface to the fourth major surface and forming a second regular pattern, the second pattern being independent of the first pattern; and   curing the curable composition to form a cured abrasive layer.   
     
     
         8 . The method of  claim 7 , wherein the attachment layer includes one part of a two-part interconnecting attachment mechanism integral to the porous backing layer. 
     
     
         9 . The method of  claim 7 , wherein the attachment layer includes one part of a two-part interconnecting attachment mechanism layer adjacent the second major surface. 
     
     
         10 . The method of  claim 7 , wherein the one part of a two-part interconnecting attachment mechanism includes at least one of a hook and a loop. 
     
     
         11 . The method of  claim 7 , wherein the releasable layer is a release liner. 
     
     
         12 . The method of  claim 7 , wherein the abrasive article further comprises at least one of a size coat and a supersize coat located adjacent the fourth major surface. 
     
     
         13 . A method of making an abrasive article, comprising:
 providing an attachment layer comprising a porous backing layer having a first major surface, an opposed second major surface and a first plurality of voids forming a first regular pattern and extending from the first major surface to the second major surface; and one part of a two-part interconnecting attachment mechanism layer adjacent the second major surface;   disposing a curable abrasive layer, having a third major surface and an opposed fourth major surface, on a releasable surface of a releasable layer, the curable abrasive layer comprising: a curable composition, abrasive particles at least partially embedded in the curable composition, and a second plurality of voids, absent of the curable composition, extending from the third major surface to the fourth major surface and forming a second regular pattern, the second pattern being independent of the first pattern;   curing the curable abrasive layer to form a cured abrasive layer on the releasable layer;   removing the releasable layer; and   adhering the cured abrasive layer to the attachment layer, wherein the first major surface of the attachment layer is adjacent the third major surface of the abrasive layer.   
     
     
         14 . The method of  claim 13 , wherein the attachment layer includes one part of a two-part interconnecting attachment mechanism integral to the porous backing layer. 
     
     
         15 . The method of  claim 13 , wherein the attachment layer includes one part of a two-part interconnecting attachment mechanism layer adjacent the second major surface. 
     
     
         16 . The method of  claim 13 , wherein the one part of a two-part interconnecting attachment mechanism includes at least one of a hook and a loop. 
     
     
         17 . The method of  claim 13 , wherein the releasable layer is a release liner. 
     
     
         18 . The method of  claim 13 , wherein the abrasive article further comprises at least one of a size coat and a supersize coat located adjacent the fourth major surface.