Curved Surface Polishing Pad With Hard Resin Layer
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Solution Overview
Problem
Existing polishing methods, such as buffing, are unable to effectively remove waviness from resin-coated surfaces with curved surfaces, resulting in an unsatisfactory surface finish.
Innovation Solution
A polishing method involving a polishing pad with a two-layer structure, comprising a hard resin layer and a soft resin layer, where the hard resin layer is supported by the soft layer to follow the curved surface, and a secondary polishing step using a pad with lower hardness, along with the use of alumina abrasive grains in a slurry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If buffing is used to polish the resin-coated surface, then the polishing process can be performed, but the waviness of the surface cannot be removed
Solution Approach 1:
The invention changes the hardness parameter of the polishing pad from soft (traditional buffing) to hard, enabling the removal of waviness while maintaining surface finish quality. This parameter change allows the polishing pad to effectively remove surface irregularities that softer materials cannot address.
2Manufacturing precision
If a hard polishing pad is used to remove waviness, then the waviness can be removed, but the contact area with curved surface decreases
Solution Approach 1:
The polishing pad is segmented into multiple layers with different hardness properties. The hard outer layer removes waviness while the softer inner layers provide flexibility to maintain contact with curved surfaces, effectively dividing the functional requirements across different structural components.
Solution Approach 2:
The invention uses a composite structure combining hard and soft materials in a layered configuration. This composite approach allows the polishing pad to simultaneously exhibit hard characteristics for waviness removal and soft characteristics for maintaining contact area on curved surfaces.
3Ease of operation
If polishing is performed on curved surfaces, then the surface can be polished, but consistent pressure application becomes difficult
Solution Approach 1:
The polishing pad incorporates dynamic flexibility through its layered structure, allowing it to adapt its shape and pressure distribution in real-time to match the contours of curved surfaces. This dynamic adaptation ensures consistent pressure application across varying surface geometries.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the effective removal of waviness and enhances polishing efficiency by increasing the contact area and maintaining consistent pressure, resulting in a smoother surface finish.
Implementation Method 1
a soft resin layer; by the buffing, it has been impossible to remove waviness of a resin-coated surface
Implementation Method 2
using slurry containing alumina abrasive grains as a polishing agent
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3D
AI summary
A polishing method capable of removing waviness on a resin-coated surface having a curved surface is provided. The resin-coated surface having the curved surface is polished by using a polishing pad (10) having a polishing surface (30) formed of a hard resin layer (40).