Abrasive article with uniform height abrasive particles

Abstract

A method of making an abrasive article including the step of preparing a master plate with a surface having a shape. Depositing a spacer layer on the surface of the master plate. A slurry containing an adhesive and abrasive particles is deposited on a surface of the spacer layer. A substrate embedded with abrasive particles having a surface generally complementary to the surface of the master plate is fabricated. A spacer layer is formed by various method controlled the height of the protruded abrasive particles. The master plate and the spacer layer are separated from the substrate to expose abrasive particle protruding a substantially uniform height. An abrasive article made according to this method is also disclosed.

1 . A method of making an abrasive article comprising:
 preparing a master plate with a surface having a shape;   depositing a spacer layer on the surface of the master plate;   distributing a slurry containing an adhesive and abrasive particles on a surface of the spacer layer, wherein the abrasive particle comprise a primary diameter greater than a thickness of the spacer layer;   pressing a substrate having a surface generally complementary to the surface of the master plate against the slurry with sufficient force to embed the abrasive particles into the substrate, and to penetrate the spacer and contact the reference plane defined by the master plate;   at least partially curing the adhesive to form a reference surface between the abrasive particles with a shape generally complementary to the surface of the spacer layer; and   separating the master plate and the spacer layer from the substrate to expose abrasive particle protruding a substantially uniform height above the reference surface formed by the cured adhesive.   
     
     
         2 . The method of  claim 1  further comprising preparing the master plate and the substrate with one of flat, concave, convex, curvilinear, spherical, or grooved surfaces. 
     
     
         3 . The method of  claim 1  wherein the step of depositing the spacer layer comprises one of spraying, coating, or printing the spacer layer on the surface of the master plate. 
     
     
         4 . The method of  claim 1  further comprising applying a hard coat to the surface of the master plate before depositing the spacer layer. 
     
     
         5 . The method of  claim 1  wherein the substrate is selected from one of metals, polymeric materials, ceramics, and composites thereof. 
     
     
         6 . A method of making an abrasive article comprising:
 preparing a master plate with a surface having a shape;   depositing a spacer layer on the surface of the master plate;   distributing a slurry containing abrasive particles on a surface of the spacer layer, wherein the abrasive particle comprise a primary diameter greater than a thickness of the spacer layer;   pressing a substrate having a surface generally complementary to the surface of the master plate against the slurry with sufficient force to embed the abrasive particles into the substrate, and to penetrate the spacer and contact the reference plane defined by the master plate;   separating the master plate and the spacer layer from the substrate to expose abrasive particle protruding a substantially uniform height above the reference surface formed by the master plate.   
     
     
         7 . The method of  claim 6  further comprising applying a hard coat to the surface of the master plate before depositing the spacer layer. 
     
     
         8 . A method of making an abrasive article comprising:
 preparing a master plate with a surface having a shape;   forming a surface barrier on the master plate;   distributing a slurry containing a carrier fluid and abrasive particles on;   evaporating carrier fluid from the slurry;   depositing a substrate layer on to the seed layer containing a bottom surface charged with abrasive particles and a top surface containing the substrate material;   releasing the substrate containing the abrasive particles from the master plate; and   etching the bottom surface of the substrate layer to reveal the abrasive particles.   
     
     
         9 . The method of  claim 8  further comprising depositing a seed layer onto the master plate containing the abrasive particles prior to the deposition of the substrate layer. 
     
     
         10 . The method of  claim 8  further comprising preparing the master plate and the substrate with one of flat, concave, convex, curvilinear, spherical, or grooved surfaces. 
     
     
         11 . The method of  claim 8  further comprising machining features into the surface of the master plate. 
     
     
         12 . The method of  claim 8  wherein depositing the spacer layer comprises one of spraying, coating, or printing the spacer layer on the surface of the master plate. 
     
     
         13 . The method of  claim 8  wherein the evaporating spacer layer is alcohol or water. 
     
     
         14 . The method of  claim 8  wherein the substrate is metallic selected from low stress electrodeposited metals and its corresponding alloys. 
     
     
         15 . A substrate article of  claim 8  further comprising a plurality of abrasive particles protruding a substantially uniform height above the etched surface. 
     
     
         16 . A method of making an abrasive article comprising:
 preparing a master plate with a surface having a shape;   distributing a slurry containing an a carrier fluid and abrasive particles on a surface of the spacer layer;   hardening the carrier fluid from the slurry;   depositing a substrate layer on to the seed layer containing a bottom surface charged with abrasive particles and a top surface containing the substrate material;   releasing the substrate containing the abrasive particles from the master plate; and   etching the bottom surface of the substrate layer to reveal the abrasive particles.   
     
     
         17 . The method of  claim 16  further comprising depositing a seed layer onto the master plate containing the abrasive particles prior to the deposition of the substrate layer. 
     
     
         18 . The method of  claim 16  further comprising preparing the master plate and the substrate with one of flat, concave, convex, curvilinear, spherical, or grooved surfaces. 
     
     
         19 . The method of  claim 16  further comprising the step of machining features into the surface of the master plate. 
     
     
         20 . The method of  claim 16  wherein depositing the spacer layer comprises one of spraying, coating, dip coating, spin coating, or printing the spacer layer on the surface of the master plate. 
     
     
         21 . The method of  claim 16  wherein the deposited material is Cupper, Nickel, Chrome, or Tin and their corresponding alloys. 
     
     
         22 . An abrasive article of  claim 16  comprising a plurality of abrasive particles protruding a substantially uniform height above the deposited seed layer. 
     
     
         23 . A method of lapping a surface of a work piece comprising:
 positioning an abrasive article opposite the surface of the work piece;   applying a lubricant to the abrasive article; and   engaging the surface of the work piece with the abrasive particles and moving the work piece relative to the abrasive article to form a substantial bearing ratio between the surface of the work piece and the reference surface on the abrasive article.   
     
     
         24 . The method of  claim 23  wherein the work piece comprises one of machined metal parts, silicon wafers, slider bars for hard disk drives.