Patent ID: 8545583

Claim:
A method of forming a flexible abrasive sheet article having an array of abrasive coated raised island structures attached to a backing sheet, the method comprising: pressing spherical abrasive beads while they are in contact with a flat plate or roll to position all of the beads into a non-solidified polymeric resin on raised island flat top surfaces to level top surfaces of individual abrasive beads into a monolayer of the spherical abrasive beads into a position within a common plane that is parallel to a bottom support surface of a backing sheet; wherein the formed flexible abrasive sheet article has features of: a) raised islands comprising a first structural material, the raised islands having the raised island flat top surfaces; b) the raised island flat top surfaces supporting the monolayer of spherical abrasive beads supported in a polymeric resin; c) the raised island structures having structural wall sides free of adhered spherical abrasive; d) the raised island structures having a structural base, the structural base having a structure base area; and e) recessed areas between structural bases of adjacent raised island structures are free of adhered, spherical abrasive beads.