# US 5,707,409 A · Abrasive article having a diamond-like coating layer and method for making same

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- Number: US 5,707,409 A
- Document ID: US5707409A
- Status: Granted
- Kind: A
- Application number: 08/698,385
- Filed: 1996-08-15
- Granted: 1998-01-13
- Earliest claimed: 1994-08-24
- Assignees: Minnesota Mining and Manufacturing Company
- Inventors: Lawrence L. Martin; David G. O'Neill; Moses M. David
- Web page: https://patentgrep.com/patent/US5707409A

## CPC

- C23C 16/0272: {Deposition of sub-layers, e.g. to promote the adhesion of the main coating}
- B24D 3/004: {with special coatings}
- B24D 3/20: and being essentially organic
- B24D 3/28: Resins {or natural or synthetic macromolecular compounds (B24D3/22 takes precedence)}
- B24D 11/00: Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
- C23C 16/26: Deposition of carbon only
- 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)
- 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)

## Abstract

An abrasive article having a sheet-like substrate having at least one major surface; an abrasive coating adhered to the at least one major surface of the substrate, wherein the abrasive coating comprises a plurality of abrasive particles and an organic binder medium; and, a hard carbon coating layer comprising a diamond-like carbon film. The hard carbon coating layer in the coated abrasive article can be provided as a top coat or, alternatively, as located between the abrasive coating and a covering layer based on an organic binder layer. The invention also pertains to a method of making such an abrasive article.

## Claims

### Claim 1

A method for making an abrasive article, comprising the steps of:
(a) providing a substrate having at least one major surface;
(b) forming an abrasive coating on said major surface, wherein said abrasive coating comprises a plurality of abrasive particles and an organic binder medium;
(c) applying sufficient current to a carbonaceous cathode to form a plasma of carbon constituents forming said cathode;
(d) permitting said plasma to be directed in a path through an anode:
(e) maintaining said abrasive coating within said path at a temperature sufficiently low effective to prevent substantial degradation of said organic binder medium to form a diamond-like carbon film on said abrasive coating, said diamond-like carbon film having an average thickness of at least about 100 Angstroms and a plasmon energy of 26 eV or more.

### Claim 2 (depends on 1)

The method of claim 1, further comprising forming a first size coat layer comprising an organic binder medium on said diamond-like carbon film.

### Claim 3 (depends on 1)

The method of claim 1, further comprising forming, after step (b) and prior to step (c), an argon plasma in the vicinity of said abrasive particles of said abrasive coating in a manner and for a time effective to remove debris from said abrasive particles.

### Claim 4 (depends on 1)

The method of claim 1, wherein said cathode comprises graphite.

### Claim 5 (depends on 1)

The method of claim 1, wherein said diamond-like carbon film has an average thickness of between 100 and 5,000 Angstroms.