Patent ID: 8795036

Claim:
A method for making a flexible abrasive disc with a pair of first and second opposed pistons and the use of an intermediary embossing mold for embossing an disc specific abrasive pattern on the disc, the abrasive disc comprising a backing with an upper side and a lower surface and a periphery; comprising the steps, in any order, of: a) creating a plurality of individual separate flexible negative image intermediary molds from a positive original mold, said original mold having a pattern formed therein corresponding to a desired abrasive structure to be formed on the disc; b) copying said pattern from said original mold to create a plurality of individual separate flexible intermediary molds by impressing said pattern from said original mold into said intermediary molds; c) applying a backing material onto said first piston; d) applying the mold onto said second piston; e) inserting abrasive agent on the mold; f) creating a vacuum in the space defined between the two pistons; g) bringing said pistons toward each other, thereby bringing said intermediary mold and backing together; h) forming a pattern on an upper surface of the backing whereby the abrasive agent is structured on said backing by said mold; i) withdrawing at least one of said pistons to expose said mold; j) curing the abrasive agent coating while the intermediary mold is still in contact therewith; k) removing the intermediate mold; l) replacing the mold after a plurality of uses with an identical mold made from said positive original.