Resin-Impregnated Knitted Lapping Material for Hard Substrates
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Solution Overview
Problem
Conventional lapping materials, such as metallic platens and common polishing cloths, are inefficient for high-hardness materials like SiC and sapphire due to low handleability and lapping rates, and require significant maintenance.
Innovation Solution
A lapping material comprising a knitted fabric impregnated with resin, featuring a regular knitting structure that enhances lapping rate and surface quality, with adjustable surface roughness and compressibility for improved handleability and maintainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a metallic platen is used for lapping high-hardness materials, then the lapping rate is improved, but the handleability and maintainability deteriorate due to heavy weight and difficulty in maintenance
Solution Approach 1:
The invention changes the material parameter of the lapping tool from metallic platen to resin-impregnated knitted fabric, which maintains the lapping performance while significantly improving handleability. The resin impregnation allows the fabric to hold abrasive grains effectively without the weight and maintenance issues of metallic platens.
Solution Approach 2:
The invention uses a composite structure combining knitted fabric with resin impregnation. This composite material approach allows the lapping tool to achieve both the mechanical performance needed for high lapping rates and the operational advantages of lightweight, easy-to-handle materials.
2Ease of operation
If a common polishing cloth is used for SiC lapping, then the handleability is improved, but the lapping rate deteriorates due to insufficient performance
Solution Approach 1:
The invention modifies the polishing cloth by impregnating it with specific resin materials and controlling the impregnation ratio. This parameter change transforms a common polishing cloth into a high-performance lapping material that can effectively process SiC while maintaining good handleability.
Solution Approach 2:
The invention applies different properties to different aspects of the lapping material: the knitted fabric structure provides flexibility and handleability, while the resin impregnation provides the hardness and abrasive retention needed for effective SiC lapping. This local differentiation of properties resolves the contradiction between handleability and lapping rate.
3Manufacturing precision
If the resin impregnation ratio is increased in the lapping material, then the surface quality is improved, but the lapping rate deteriorates
Solution Approach 1:
The invention optimizes the resin impregnation ratio as a critical parameter, finding the optimal balance point where surface quality is sufficiently improved without excessively sacrificing lapping rate. The patent specifies controlling the resin content within a particular range to achieve this balance.
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 lapping material achieves a high lapping rate comparable to metallic platens while offering improved handleability and maintainability, suitable for both primary and secondary lapping applications, and produces polished products with enhanced surface quality.
Implementation Method 1
a lapping material comprising a knitted fabric impregnated with resin
Data Source
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Figure 2
AI summary
A lapping material having a knitted fabric constituted by warp knitting or weft knitting, and a resin with which the knitted fabric is impregnated.