# US 2022/0033950 A1 · Coated abrasive tool, method for producing the same and abrasive dental product > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0033950 A1 - Document ID: US20220033950A1 - Status: Published application - Kind: A1 - Application number: 17/502,892 - Filed: 2021-10-15 - Published: 2022-02-03 - Earliest claimed: 2019-04-18 - Assignees: ecoCOAT GmbH - Applicants: ecoCOAT GmbH - Inventors: Reinhold RIEMENSPERGER; Enrico FLADE - Web page: https://patentgrep.com/patent/US20220033950A1 ## CPC - C23C 4/04: characterised by the coating material - A46B 9/005: {where the brushing material is not made of bristles, e.g. sponge, rubber or paper} - A46B 9/04: {Arranged like in or} for toothbrushes - A61C 3/025: Instruments acting like a sandblast machine, e.g. for cleaning, polishing or cutting teeth - A61C 3/06: Tooth grinding or polishing discs; Holders therefor {(prophylactic cups A61C17/005)} - B24D 3/007: {the constituent being used as bonding agent between different parts of an abrasive tool} - B24D 3/20: and being essentially organic - C23C 4/134: Plasma spraying - C23C 24/08: by application of heat or pressure and heat (C23C24/04 takes precedence) - A46B 2200/3093: Brush with abrasive properties, e.g. wire bristles - A61C 17/222: {Brush body details, e.g. the shape thereof or connection to handle} - B82Y 40/00: Manufacture or treatment of nanostructures - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - A46B: BRUSHES (handles not integral with brushware B25G) - A61C: DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE (non-driven toothbrushes A46B; {tongue scrapers A61B17/24;} preparations for dentistry A61K6/00; preparations for cleaning the teeth or mouth A61K8/00, A61Q11/00) - B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11) - B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES ## Abstract The invention relates to a coated abrasive tool including a carrier which has a carrier material and including an abrasive surface coating on a surface region of the carrier. The abrasive surface coating has abrasive functional particles and a thermoplastic binder for an adhesive connection between at least some of the abrasive functional particles and the carrier material. At least some of the abrasive functional particles on the surface region of the carrier are partly integrated into the carrier material and are connected to the carrier material, and at least some of the abrasive functional particles on the surface region of the carrier are additionally partly integrated into the thermoplastic binder, the thermoplastic binder being connected to the abrasive functional particles and the carrier material. ## Claims ### Claim 1 A coated abrasive tool, comprising: a carrier comprising a carrier material, and an abrasive surface coating on a surface area of the carrier, wherein the abrasive surface coating comprises abrasive functional particles and a thermoplastic binder for an adhesive bond between at least part of the abrasive functional particles and the carrier material, wherein at least part of the abrasive functional particles on the surface area of the carrier is partially embedded in and bonded to the carrier material, and wherein at least part of the abrasive functional particles on the surface area of the carrier is further partially embedded in the thermoplastic binder, wherein the thermoplastic binder is bonded to the abrasive functional particles and the carrier material. ### Claim 2 (depends on 1) The coated abrasive tool according to claim 1, wherein the abrasive functional particles comprise an average diameter d1, wherein at least part of the abrasive functional particles of the abrasive surface coating is embedded in an embedding depth d2 of the carrier material, wherein the embedding depth d2 corresponds to at least 5% and at most 95% of the average diameter d1 of the abrasive functional particles. ### Claim 3 (depends on 1) The coated abrasive tool according to claim 1, wherein at least 60% of the area of the abrasive surface coating is covered with a monolayer of the abrasive functional particles on the surface area of the carrier. ### Claim 4 (depends on 1) The coated abrasive tool according to claim 1, wherein the average thickness d4 of the deposited thermoplastic binder is smaller than the average diameter d1 of the abrasive functional particles and the abrasive functional particles protrude from the thermoplastic binder. ### Claim 5 (depends on 1) The coated abrasive tool according to claim 1, wherein the surface portion of the carrier is profiled and comprises knobs, a pyramid shape, a truncated pyramid shape, a cone shape, a truncated cone shape, groove structure, spiral structure or in cross-section a wave shape, wherein the abrasive functional particles are configured as a monolayer in combination with the thermoplastic binder. ### Claim 6 (depends on 1) The coated abrasive tool according to claim 1, wherein the carrier material comprises an open-pored surface area with an average pore diameter d3, wherein the functional particles comprise an average diameter d1 with d1≤¼ d3, wherein the abrasive functional particles are configured as a monolayer in combination with the thermoplastic binder. ### Claim 7 (depends on 1) The coated abrasive tool according to claim 1, wherein the carrier material comprises cork, textile, rubber, elastomer, PVC, PUR, paper, latex, PE, PA, PET, PC, SBR, PTHF, carbonate, a foam material, a bristle material of a brush and/or a foil material. ### Claim 8 (depends on 1) The coated abrasive tool according to claim 1, wherein the abrasive functional particles are configured as hard particles and comprise corundum, zirconia corundum, silicon carbide, boron nitride, glass, minerals, natural materials or diamond with a particle size between 100 nm and 2 mm. ### Claim 9 (depends on 1) The coated abrasive tool according to claim 1, wherein the thermoplastic binder comprises PE, PA, PC, ABS, PVC, PET, PEEK, PTFE, PUR, PMMA or PTHF. ### Claim 10 (depends on 1) The coated abrasive tool according to claim 1, wherein the coated abrasive tool is configured as a grinding tool, a polishing tool, a cleaning body or a brush. ### Claim 11 (depends on 1) The coated abrasive tool according to claim 1, wherein the abrasive effect of the abrasive tool is adjusted via the distribution density and/or size of the abrasive functional particles on the surface area of the carrier. ### Claim 12 (depends on 1) The coated abrasive tool according to claim 1, further comprising: an additional surface covering material on the existing abrasive surface coating, the additional surface covering material comprising a dry lubricant property. ### Claim 13 A method for producing a coated abrasive tool, comprising: supplying a powder mixture to a thermal or low-thermal plasma spraying apparatus directed onto a surface area of a carrier to be coated, wherein the powder mixture comprises abrasive functional particles and a thermoplastic binder, wherein the powder mixture comprises the functional particles and the thermoplastic binder material as separate powder particles, or wherein the powder mixture comprises the functional particles at least partially or completely clad with the thermoplastic binder, and wherein a reduction in the viscosity of the binder is effected in the thermal or low-thermal plasma spraying apparatus, and depositing the functional particles with the reduced viscosity binder on a surface area of the carrier, wherein the thermoplastic binder re-solidifies upon deposition on the surface area of the carrier and the abrasive surface coating is formed on the carrier of the abrasive tool with the functional particles and the thermoplastic binder. ### Claim 14 (depends on 13) The method of claim 13, wherein depositing the abrasive functional particles on the surface area of the carrier further effects partial embedding of at least part of the abrasive functional particles in an embedding depth d2 of the carrier material of the carrier, wherein the embedding depth d2 corresponds to at least 5% and at most 95% of an average diameter d1 of the abrasive functional particles, with 0.95 d1≥d2≥0.05 d1. ### Claim 15 (depends on 13) The method according to claim 13, further comprising: adjusting the distribution density of the functional particles on the surface via the portion of the abrasive functional particles in the mixture of thermoplastic binder and functional particles supplied to the plasma spraying apparatus in order to deposit the abrasive functional particles as a monolayer in combination with the thermoplastic binder. ### Claim 16 (depends on 13) The method according to claim 13, further comprising: adjusting the powder conveying amount and feed over the carrier surface so that when depositing the abrasive functional particles and thermoplastic binder, at least 60% of the area of the abrasive surface coating is formed as a monolayer of the abrasive functional particles in combination with the thermoplastic binder on the surface area of the carrier. ### Claim 17 (depends on 13) The method according to claim 13, wherein the carrier comprises an open-pored surface area comprising an average pore diameter d3, wherein the functional particles comprise an average diameter d1 with d1≤½ d3 to effect an adhesive bond of the abrasive surface coating following the topography of the open-pored surface area in a close-contour manner as a monolayer on the open-pored carrier surface. ### Claim 18 (depends on 13) The method according to claim 13, wherein the carrier material comprises cork, textile, rubber, elastomer, PVC, PUR, paper, latex, PE, PA, PET, PC, SBR, PTHF, carbonate, a foam material, a bristle material of a brush and/or a foil material. ### Claim 19 (depends on 13) The method according to claim 13, wherein the abrasive functional particles are configured as hard particles and comprise corundum, zirconium corundum, silicon carbide, boron nitride, glass, minerals, natural materials or diamond comprising a particle size between 100 nm and 2 mm, and wherein the thermoplastic binder comprises PE, PA, PC, ABS, PVC, PET, PEEK, PTFE, PUR, PMMA or PTHF. ### Claim 20 (depends on 13) The method according to claim 13, wherein the thermoplastic binder and the abrasive functional particles are simultaneously deposited on the surface area of the carrier. ### Claim 21 (depends on 1) An abrasive dental product comprising the coated abrasive tool according to claim 1. ### Claim 22 (depends on 21) The abrasive dental product according to claim 21, wherein the carrier comprises a foam material as the carrier material, the abrasive surface coating being arranged on a surface area of the foam material. ### Claim 23 (depends on 22) The abrasive dental product according to claim 22, wherein the foam material is open-pored and elastically deformable. ### Claim 24 (depends on 21) The abrasive dental product according to claim 21, wherein the carrier comprises a support structure on which the carrier material is arranged, the carrier material being mechanically mounted to the support structure and surrounding the support structure in areas or in a cap-like manner. ### Claim 25 (depends on 21) The abrasive dental product according to claim 21, wherein the coated abrasive tool is configured as a cleaning grinding pad comprising a flat grinding surface or an outwardly curved (convex) grinding surface. ### Claim 26 (depends on 21) The abrasive dental product according to claim 21, wherein the foam material is configured to receive a cleaning fluid, wherein based on the porosity of the foam material and the viscosity of the cleaning fluid, the delivery of the cleaning fluid in use is adjustable. ### Claim 27 (depends on 21) The abrasive dental product according to claim 21, wherein the abrasive dental product is a dental cleaning product, wherein the coated abrasive tool is arranged as a cleaning grinding pad on the dental cleaning product. ### Claim 28 (depends on 27) The abrasive dental product according to claim 27, wherein the dental cleaning product is a toothbrush head of an electric or manual toothbrush, wherein the coated abrasive tool is arranged as a cleaning grinding pad on the toothbrush head. ### Claim 29 (depends on 28) The abrasive dental product according to claim 28, wherein the toothbrush head comprises the cleaning grinding pad and further cleaning bristles laterally adjacent to or laterally surrounding the cleaning grinding pad. ### Claim 30 (depends on 28) The abrasive dental product according to claim 28, wherein the cleaning grinding pad is interchangeably or fixedly arranged on the support structure. ### Claim 31 (depends on 21) The abrasive dental product according to claim 21, wherein the abrasive functional particles comprise a thermoplastic material. ### Claim 32 (depends on 31) The abrasive dental product according to claim 31, wherein the thermoplastic material of the abrasive functional particles is harder than the thermoplastic binder. ### Claim 33 (depends on 21) The abrasive dental product according to claim 21, wherein the abrasive surface coating comprises an additional material in the form of nanoparticles or microparticles comprising an antibacterial and/or antiviral effect. ### Claim 34 (depends on 21) The abrasive dental product according to claim 21, wherein the dental cleaning product is configured as a dental polisher, a dental drill attachment comprising a polishing and/or smoothing surface, or a dental polishing pen. ### Claim 35 (depends on 1) A dental cleaning product in the shape of a toothbrush head of an electric or manual toothbrush, comprising: the coated abrasive tool according to claim 1, wherein the coated abrasive tool is arranged on the toothbrush head as a cleaning grinding pad, and wherein the carrier comprises a foam material as the carrier material, wherein the abrasive surface coating is arranged on a surface area of the foam material. ### Claim 36 A coated abrasive tool, comprising: a carrier comprising a backing material, and an abrasive surface coating on a surface area of the carrier, wherein the abrasive surface coating comprises grinding grains and a thermoplastic binder for an adhesive bond between at least part of the grinding grains and the carrier material, wherein at least part of the grinding grains is partially embedded in the carrier material on the surface area of the carrier and is connected to the carrier material in a form-fitting manner, wherein at least part of the grinding grains on the surface area of the carrier is further partially embedded in the thermoplastic binder, wherein the thermoplastic binder is connected to the grinding grains and the carrier material in an integrated and/or form-fitting manner, wherein the grinding grains comprise an average diameter d1, wherein at least part of the grinding grains of the abrasive surface coating is embedded in an embedding depth d2 of the carrier material, wherein the embedding depth d2 corresponds to at least 5% and at most 95% of the average diameter d1 of the grinding grains, wherein at least 60% of the area of the abrasive surface coating is covered with a monolayer of the grinding grains on the surface area of the carrier, and wherein the average thickness d4 of the deposited thermoplastic binder is smaller than the average diameter d1 of the grinding grains and the grinding grains protrude from the thermoplastic binder.