Patent ID: 6989117

Claim:
A method of making a polishing pad, comprising a body comprising fibers embedded in a matrix polymer formed by a reaction of polymer precursors, said fibers defining interstices, and said precursors filling said interstices substantially completely before completion of said reaction, said method comprising: placing said fibers and said precursors in a cavity of a mold for shaping said pad; applying a differential pressure across said mold cavity, said differential pressure and the amount of said precursors being sufficient to cause said precursors to fill said interstices substantially completely before completion of said reaction; applying sufficient heat to said mold to at least partially cure said pad by causing said precursors to react; further comprising removing said cured pad from said mold cavity and buffing at least one side of said cured pad with an abrasive device for fracturing and removing a portion of said polymer to form a polishing layer of free fibers, at least a portion of said free fibers being embedded in un-fractured matrix polymer of said body adjacent to said polishing layer.