Backingless Abrasive Article

Abstract

An abrasive article includes an abrasive layer having an array of protrusions. The abrasive layer has a thickness not greater than about 500 mils. The abrasive article is free of a backing layer.

What is claimed is: 
     
         1 . A method of making an abrasive article, comprising the steps of:
 forming an abrasive layer having first and second major sides, the abrasive layer including a blend of a polymer formulation and abrasive grains;   patterning the first major side of the abrasive layer to define a set of protrusions extending from a first surface of the abrasive article, and   disposing an adhesive layer on the second major side of the abrasive layer,   wherein the polymer formulation includes a liquid silicone rubber, and   wherein the abrasive layer has a total height not greater than 500 mils, the set of protrusions extend not greater than 20 mils, and the adhesion layer is in direct contact with the second major side, the adhesion layer defining a second surface of the abrasive article.   
     
     
         2 . The method of  claim 1 , wherein the forming is accomplished by extrusion or calendaring. 
     
     
         3 . The method of  claim 2 , wherein the abrasive layer is formed into a sheet. 
     
     
         4 . The method of  claim 2 , wherein the abrasive layer is formed onto a negative surface, the negative surface including a negative pattern. 
     
     
         5 . The method of  claim 2 , wherein the forming is by extrusion of the polymer formulation onto a negatively patterned mold. 
     
     
         6 . The method of  claim 1 , wherein patterning includes stamping, rolling, embossing, and/or engraving. 
     
     
         7 . The method of  claim 1 , wherein forming is by compression molding.