Abrasive sheet including a plurality of protrusions

Abstract

Various embodiments disclosed relate to an abrasive sheet. The abrasive sheet includes a first layer including an abrasive major surface and an opposite second layer defining a second major surface. The second major surface includes a plurality of protrusions extending outwardly from the second major surface. The protrusions include a first polymer component having at least one of a Shore A hardness ranging from about 5 to about 100 and a Shore D hardness ranging from about 1 to about 70. The first layer and the second layer are directly joined to each other.

1 . An abrasive sheet comprising:
 a first layer comprising an abrasive first major surface; and   an opposite second layer defining a second major surface comprising:
 a plurality of protrusions extending outwardly from the second major surface, wherein the protrusions comprise a first polymer component having at least one of a Shore A hardness ranging from about 5 to about 100 and a Shore D hardness ranging from about 1 to about 70, 
   wherein the first layer directly contacts the second layer, and   wherein the protrusions are free of any undercuts.   
     
     
         2 . The abrasive sheet of  claim 1 , wherein the first polymer component ranges from about 50 wt % to about 100 wt % of the individual protrusions. 
     
     
         3 . The abrasive sheet of  claim 1 , wherein the protrusions have a height-to-width aspect ratio ranging from about 0.5 to about 10. 
     
     
         4 . The abrasive sheet of  claim 1 , wherein the protrusions have a height ranging from about 10 micrometers to about 800 micrometers. 
     
     
         5 . The abrasive sheet of  claim 1 , wherein the protrusions have a height ranging from about 50 micrometers to about 600 micrometers. 
     
     
         6 . The abrasive sheet of  claim 1 , wherein the protrusions have a height ranging from about 100 micrometers to about 800 micrometers. 
     
     
         7 . The abrasive sheet of  claim 1 , wherein the first polymer component comprises one or more polymers. 
     
     
         8 . The abrasive sheet of  claim 7 , wherein the one or more polymers is an elastomer chosen from a polyurethane, a styrene-ethylene-butylene-styrene block copolymer, a styrene-isoprene-styrene block copolymer, or mixtures thereof. 
     
     
         9 . An abrasive sheet of  claim 1 , wherein the abrasive first surface comprises a plurality of abrasive particles. 
     
     
         10 . A method of making an abrasive sheet comprising:
 forming a first assembly, the first assembly comprising:
 a support having a plurality of holes defined on a support major surface; and 
 a first polymer component at least partially filling at least one of the holes of the support and forming a layer thereon; and 
   coating the first polymer component with an abrasive material.   
     
     
         11 . The abrasive sheet of  claim 10 , wherein the first polymer component comprises one or more polymers chosen from a polyurethane, a styrene-ethylene-butylene-styrene block copolymer, a styrene-isoprene-styrene block copolymer, or mixtures thereof. 
     
     
         12 . The method of  claim 10 , wherein the support surface is stiffer than the first polymer component. 
     
     
         13 . The method of  claim 10 , wherein the support comprises a support polymer component. 
     
     
         14 . The method of  claim 13 , wherein the support polymer component comprises one or more polymers chosen from polypropylene, a polycarbonate, a polyurethane, polyethylene, polyamide, polyester, polyester terephthalate, glycol-modified polyethylene terephthalate, copolymers thereof, or mixtures thereof. 
     
     
         15 . The method of  claim 10 , wherein forming the first assembly includes extrusion or hot-pressing. 
     
     
         16 . The method of  claim 10 , further comprising cooling the abrasive sheet. 
     
     
         17 . The method of  claim 10 , further comprising removing the support to expose the plurality of protrusions. 
     
     
         18 . The method of  claim 10 , further comprising forming the support. 
     
     
         19 . A method of using the abrasive sheet of  claim 1 , comprising:
 frictionally engaging the plurality of protrusions with a substrate;   engaging the abrasive first major surface with a working surface of an object;   moving the abrasive sheet relative to the working surface to abrade the working surface.   
     
     
         20 . The method of  claim 19  further comprising:
 rubbing the plurality of protrusions against the working surface of the object to dislodge swarf or debris thereon.