Interrupted Abrasive Article for Single-Sided Polishing
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Solution Overview
Problem
Single-sided polishing processes often result in incomplete polishing of workpieces due to the workpiece not being fully cleared across the entire surface, especially when it cannot freely rotate with respect to the carrier.
Innovation Solution
The use of an interrupted structured abrasive article with open regions on a polishing member, allowing the workpiece to rotate independently and ensuring that at least 30% of its surface can be superimposed within these open regions, while not exceeding 90% coverage, to effectively abrade the workpiece surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a continuous structured abrasive article is used in single-sided polishing, then the polishing coverage is maximized, but the workpiece surface uniformity deteriorates due to incomplete clearing
Solution Approach 1:
The continuous abrasive article is divided into multiple discrete abrasive regions separated by open spaces. This segmentation allows different zones to perform different functions: some regions provide abrasive action while open regions allow workpiece rotation and material removal from the center, achieving both coverage and uniformity.
Solution Approach 2:
Different regions of the abrasive article are designed with different properties - abrasive regions for material removal and open regions for workpiece rotation and clearing. This local differentiation enables the system to achieve both polishing coverage and surface uniformity simultaneously.
2Device complexity
If the workpiece is constrained to rotate with the carrier, then the polishing process is simplified, but the clearing efficiency deteriorates
Solution Approach 1:
The system transitions from a static rotation constraint to a dynamic configuration where the workpiece can independently rotate within the carrier. This dynamic freedom allows the workpiece to clear its center region effectively while maintaining contact with the abrasive article.
3Productivity
If polishing pressure is increased to improve clearing, then the material removal rate increases, but the risk of workpiece damage and subsurface damage increases
Solution Approach 1:
The abrasive article is segmented into discrete regions that distribute the polishing load across multiple contact zones. This prevents concentration of excessive pressure at any single point, enabling effective clearing at lower overall pressures and reducing the risk of workpiece damage.
4Area of stationary object
If the abrasive article covers the entire workpiece surface, then the polishing coverage is maximized, but the workpiece center clearing deteriorates
Solution Approach 1:
The abrasive article pattern is segmented to include open regions that correspond to the workpiece center area. This allows the workpiece to rotate and clear its center region while the surrounding abrasive regions provide polishing coverage, solving both coverage and clearing quality simultaneously.
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 ensures a uniformly polished surface, as demonstrated by the ability to clear the workpiece surface within a shorter polishing time compared to conventional methods, even at lower pressures, indicating improved polishing efficiency.
Implementation Method 1
the abrasive layer comprises shaped abrasive composites comprising abrasive particles retained in a binder material... rotating the polishing member and the carrier member to abrade the outer major surface of the workpiece
Data Source
AI summary
Interrupted structured abrasive articles comprise an abrasive layer comprising shaped abrasive composites that extend outwardly from a first major surface of a backing to which they are secured. The abrasive layer defines at least one open region that is free of the shaped abrasive composites and may extend partially or completely through the backing. In some embodiments, each of the open regions comprises a circular area of at least 1.5 square centimeters, and when combined the open regions have total area that is at least 10 percent of the area of the first major surface of the backing. Interrupted abrasive articles are useful in single-sided polishing processes.