초록

An abrasive article having an apertured coated abrasive member, filter media, and an attachment interface member is formed by an ultrasonic welding process. The abrasive article is useful for abrading a workpiece.

대표청구항 ▼

What is claimed is: 1. An abrasive article comprising: an apertured coated abrasive member comprising abrasive particles secured to a first major surface of a thin flexible incompressible backing by make and size layers; and an adhesive layer adhered to a second major surface, opposite the first ma

What is claimed is: 1. An abrasive article comprising: an apertured coated abrasive member comprising abrasive particles secured to a first major surface of a thin flexible incompressible backing by make and size layers; and an adhesive layer adhered to a second major surface, opposite the first major surface, of the backing, wherein apertures extend through the abrasive layer, the backing, and the adhesive layer; a first filter medium having a first surface and a second surface opposite the first surface, the first surface of the first filter medium adhered to the adhesive layer of the apertured coated abrasive member, the first filter medium defining discrete channels formed by channel sidewalls, the discrete channels extending from the first surface of the first filter medium to the second surface of the first filter medium; a second filter medium having first and second opposed surfaces, wherein the first surface of the second filter medium is proximate the second surface of the first filter medium at an interface; and an attachment interface member affixed to the second surface of the second filter medium, wherein the attachment interface member comprises fabric and has a back surface proximate to the second filter medium and an outwardly disposed engageable surface opposed to the back surface; wherein at least a portion of the apertures cooperate with at least a portion of the discrete channels to allow a flow of particles from the apertured coated abrasive member to the second filter medium, wherein the first filter medium, the second filter medium, and the attachment interface member are joined together by at least one weld situated at the interface. 2. An abrasive article according to claim 1, wherein the first filter medium, the second filter medium, and the attachment interface member are joined together by a weld that comprises a continuous network of intersecting lines or line segments. 3. An abrasive article according to claim 1, wherein the first filter medium, the second filter medium, and the attachment interface member are joined together by at least 20 welds. 4. An abrasive article according to claim 1, wherein the welds have a maximum width in a range of from 1 to 10 millimeters. 5. An abrasive article according to claim 1, wherein the first filter medium has a maximum thickness in a range of 1 to 20 millimeters. 6. An abrasive article according to claim 1, wherein the channel sidewalls comprise polymer film. 7. An abrasive article according to claim 1, wherein the discrete channels have an average effective circular diameter of at least 0.1 millimeter. 8. An abrasive article according to claim 1, wherein the second filter medium comprises a nonwoven filter. 9. An abrasive article according to claim 1, wherein at least one of the first filter medium or the second filter medium has an electret charge. 10. An abrasive article according to claim 1, wherein the attachment interface member comprises a loop portion of a two-part mechanical engagement system. 11. An abrasive article according to claim 1, wherein the first filter medium, second filter medium, and attachment interface member each comprise polypropylene. 12. An abrasive article according to claim 1, wherein the abrasive article comprises an abrasive disk. 13. An abrasive article according to claim 1, wherein the abrasive particles have an average particle size of 50 micrometers or less. 14. A method of abrading a surface of a workpiece comprising frictionally contacting the surface of the workpiece with an abrasive article according to claim 1, and relatively moving the abrasive article and the surface to abrade the surface. 15. A method of abrading a surface of a workpiece according to claim 14, wherein the first filter medium, second filter medium, and attachment interface member each comprise polypropylene. 16. A method of making an abrasive article, the method comprising: providing an apertured coated abrasive member comprising abrasive particles secured to a first major surface of a thin flexible incompressible backing by make and size layers; and an adhesive layer adhered to a second major surface, opposite the first major surface, of the backing, wherein apertures extend through the abrasive layer, the backing, and the adhesive layer; providing a first filter medium having a first surface and a second surface opposite the first surface, the first filter medium defining discrete channels formed by channel sidewalls, the discrete channels extending from the first surface of the first filter medium to the second surface of the first filter medium; providing a second filter medium having first and second opposed surfaces; providing an attachment interface member comprising fabric and having a back surface and an engageable surface opposed to the back surface; contacting the first surface of the second filter medium with the second surface of the first filter medium; contacting the back surface of the attachment interface member and the second surface of the second filter medium; forming at least one weld joining the first filter medium, the second filter medium, and the attachment interface member, wherein the weld is situated at the second surface of the first medium; and adhering the adhesive layer of the apertured coated abrasive member to the first surface of the first filter medium, wherein at least a portion of the apertures cooperate with at least a portion of the discrete channels to allow a flow of particles from the apertured coated abrasive member to the second filter medium. 17. A method according to claim 16, wherein the first filter medium, the second filter medium, and the attachment interface member are joined together by a weld that comprises a continuous network of intersecting line segments. 18. A method according to claim 16, wherein the first filter medium, the second filter medium, and the attachment interface member are joined together by at least 20 welds. 19. A method according to claim 16, further comprising bonding the first filter medium to the second filter medium prior to joining the first filter medium, the second filter medium, and the attachment interface member. 20. A method according to claim 16, wherein the first filter medium, second filter medium, and attachment interface member each comprise polypropylene. 21. A method according to claim 16, wherein said at least one weld is formed by a process comprising: contacting the first surface of the first filter medium with one of an ultrasonic welding horn or anvil, contacting the engageable surface of the attachment interface member with the other of the ultrasonic welding horn or anvil and ultrasonically forming at least one weld joining the first filter medium, the second filter medium, and the attachment interface member.