Diamond Polishing Sheet Composition for Uniform Repeated Finishing
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Solution Overview
Problem
Existing polishing materials struggle to form a uniform smooth surface with low convexities and concavities, especially when repeated polishing is performed on the same surface, due to issues with polishing debris adhesion and decreased performance.
Innovation Solution
A polishing sheet comprising a substrate, three-dimensional elements with diamond abrasive particles, and an intermediate layer, with a specific mass ratio of abrasive particles to bonding material (C2/C1) between 0.05 to 1.5, which enhances polishing efficiency and uniformity even with repeated use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional polishing materials are used for repeated polishing, then polishing speed may be maintained, but surface uniformity deteriorates due to debris adhesion and convexities/concavities formation
Solution Approach 1:
The polishing sheet is divided into three distinct functional layers: a substrate layer, an intermediate layer with specific adhesive properties, and a polishing layer containing abrasive particles. This segmentation allows each layer to perform its specific function optimally, preventing debris adhesion and maintaining surface uniformity during repeated polishing operations
Solution Approach 2:
The invention uses a composite structure combining different materials with specific properties: the substrate provides mechanical support, the intermediate layer provides controlled adhesion, and the polishing layer contains abrasive particles bonded with specific bonding materials. This composite material approach enables the polishing sheet to maintain performance consistency while achieving uniform surfaces
2Productivity
If high concentration of abrasive particles is used, then polishing efficiency improves, but surface uniformity deteriorates due to increased convexities and concavities
Solution Approach 1:
The intermediate layer is designed with specific local properties including controlled adhesive force and specific thickness (5-50 μm) to locally control the distribution and embedding depth of abrasive particles. This local quality control ensures that abrasive particles are properly embedded without creating excessive convexities, maintaining surface uniformity while preserving polishing efficiency
Solution Approach 2:
The invention optimizes specific parameters including the adhesive force of the intermediate layer (0.5-5 N/mm), the thickness of the intermediate layer (5-50 μm), and the mass ratio of abrasive particles to bonding material (0.05-1.5). These parameter changes enable high abrasive concentration while maintaining surface uniformity by controlling particle embedding and distribution
3Strength
If strong bonding material is used to secure abrasive particles, then abrasive retention improves, but polishing performance deteriorates due to excessive adhesion preventing effective material removal
Solution Approach 1:
The intermediate layer's adhesive force is precisely controlled within the range of 0.5-5 N/mm, and the mass ratio of abrasive particles to bonding material is optimized to 0.05-1.5. These parameter changes ensure that abrasive particles are securely retained during repeated polishing while maintaining sufficient polishing efficiency by preventing excessive adhesion that would hinder material removal
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
The polishing sheet effectively forms a smooth surface with low convexities and concavities, maintaining polishing performance and preventing debris adhesion, even under high loads and repeated use.
Implementation Method 1
a plurality of three-dimensional elements which contain diamond abrasive particles (C2) and a bonding material (C1) and form a polishing surface
Data Source
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Figure 3A~3B
Figure 4A~4B
AI summary
[Problem] To provide a polishing sheet in which a hard material such as a metal product can be efficiently polished to form a smooth surface with low convexities and concavities, and to form a uniform smooth surface even when repeated polishing is performed on the same polishing surface. [Resolution Means] A polishing sheet includes a substrate, a plurality of three-dimensional elements that includes diamond abrasive particles and a bonding material, and forms a polishing surface, and an intermediate layer that is provided between the substrate and the three-dimensional element and bonds the substrate and the three-dimensional element together, wherein a ratio C2/C1 of a content of the diamond abrasive particles C2 to a content of the bonding material C1 is 0.05 to 1.5 in terms of mass ratio.