Embedded-Abrasive Polishing Disc for Cleaner Mirror Finishing
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Solution Overview
Problem
Conventional polishing discs for glass or sapphire panels in electronic products suffer from high cost, low efficiency, and serious environmental pollution due to the need for polishing powder and liquid, leading to uneven polishing and environmental degradation.
Innovation Solution
An environment-friendly polishing disc comprising a lower backsheet, a soft polishing layer made of polyurethane synthetic resin containing polishing powder, and an upper backsheet, which interacts with industrial electronic products in tap water, reducing the need for additional polishing powder and liquid, and featuring a special groove strip for debris removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional polishing discs with metal or single soft polishing material are used, then polishing capability is achieved, but cost increases and environmental pollution occurs due to continuous addition of polishing powder and liquid
Solution Approach 1:
The invention combines the polishing powder directly into the polishing disc structure by integrating alumina particles into a polyurethane matrix, merging the polishing function with the disc body. This eliminates the need for separate polishing powder and liquid additions, reducing environmental pollution while maintaining polishing capability.
Solution Approach 2:
The polishing disc is designed to be self-sufficient with polishing powder embedded in its structure, allowing it to perform polishing functions without external assistance of polishing liquids or frequent powder additions. The disc serves its own polishing needs through the embedded abrasive particles.
2Ease of operation
If conventional polishing discs require continuous addition of polishing powder and liquid, then polishing operation is maintained, but polishing efficiency decreases and cost increases
Solution Approach 1:
The polishing disc contains embedded alumina particles within the polyurethane matrix, enabling it to maintain polishing operation continuously without requiring external powder additions or liquid applications, thereby improving polishing efficiency and operational simplicity.
Solution Approach 2:
The invention uses a composite material structure where alumina particles are distributed within a polyurethane matrix, creating a material that combines the softness of polyurethane with the abrasive properties of alumina, enabling continuous efficient polishing without additional agents.
3Object-affected harmful factors
If soft polishing materials like leather or wool are used, then the polishing disc is gentle on workpiece, but tensile strength is low and service life is short
Solution Approach 1:
The invention creates a composite material where alumina particles are embedded in a polyurethane matrix, combining the softness and gentleness of polyurethane with the abrasive capability of alumina, achieving both workpiece protection and extended disc service life through enhanced tensile strength.
Solution Approach 2:
The polishing disc features localized abrasive particles (alumina) distributed within the soft polyurethane matrix, creating different functional zones: the soft matrix protects the workpiece while the embedded abrasive particles provide polishing action, achieving both gentleness and durability.
4Power
If metal polishing discs with high hardness are used, then polishing power is sufficient, but the suitable surface range is narrow and machining requirements are many
Solution Approach 1:
The invention changes the hardness parameter of the polishing disc by using a polyurethane matrix with embedded alumina particles, creating a medium-hardness disc that can adapt to various surface types. This flexibility in hardness parameter allows the disc to be suitable for different workpiece materials and surface conditions.
Solution Approach 2:
The polishing disc with polyurethane matrix and embedded alumina particles achieves multi-functionality by being suitable for polishing various surfaces including glass, sapphire, and other hard materials, replacing the need for multiple specialized discs with different hardness levels.
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 solution enhances polishing efficiency, achieves a mirror optical effect with uniform refractive index, reduces environmental pollution, and extends the disc's lifespan by minimizing the use of polishing agents and improving the polishing finish.
Implementation Method 1
adding the polishing powder and the polyester synthetic resin containing HC8968 and HC8552 into the batching barrel, and uniformly mixing the polishing powder and the polyester synthetic resin containing HC8968 and HC8552 with a vibrator
Implementation Method 2
the rare earth powder special synthetic resin combination can its wear resistance and grinding force, and the polishing sheet structure can quickly remove the debris due to the existence of the special groove strip
Implementation Method 3
the soft polishing layer is made of polyurethane synthetic resin containing polishing powder... achieves a mirror optical effect with uniform refractive index
Data Source
AI summary
An environment-friendly polishing disc is manufactured by a processing technology that includes: preparing a table, drying oven, cutting tools, upper and lower molds, polishing powder, a batching barrel, and a polyurethane synthetic resin comprising HC8968 and HC8552; cutting a polyester-fiber upper backsheet and a lower backsheet to match the mold profile; batching the polishing powder with the polyurethane resin and uniformly mixing with a vibrator; pouring the mixture into the lower mold over the lower backsheet, scraping the surface, overlaying the upper backsheet, and clamping with the upper mold; sequentially drying the clamped assembly at about 45° C. for about 230 min, about 92° C. for about 230 min, and about 60° C. for about 450 min; and removing the molds to form the disc. An optional central notch may be provided. The process reduces external polishing consumables and supports uniform soft-layer formation.