Lubricant Composition for Lapping Ceramic Sliders
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Solution Overview
Problem
Existing lubricant compositions for lapping slider bars in the HDD industry fail to effectively manage swarf buildup and heat dissipation, leading to reduced lapping plate life and surface scratching, especially when lapping multiple bars simultaneously.
Innovation Solution
A lubricant composition is developed by mixing a base lubricant with a powdered wax component, either as a dispersion or emulsion, which is applied to the lapping surface to repel swarf and facilitate heat dissipation, using materials like PTFE to enhance electronegative properties and prevent swarf adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lubricant compositions are used for lapping slider bars, then lapping can proceed, but swarf buildup occurs on the lapping plate leading to reduced lapping plate life and surface scratching
Solution Approach 1:
The patent introduces an intermediary substance (lubricant composition containing electronegative materials like PTFE) that mediates between the abrasive lapping plate and the ceramic slider bars. This intermediary repels swarf particles through electronegative properties, preventing swarf adherence to the lapping plate surface while still allowing effective material removal and extending lapping plate life
Solution Approach 2:
The patent changes the chemical parameter of the lubricant composition by incorporating materials with specific electronegativity values (e.g., PTFE with high electronegativity). This parameter change enables the lubricant to repel swarf particles electrostatically, transforming the lubricant from a simple lubricating agent to an active swarf-repelling composition that prevents buildup and scratching
2Productivity
If lapping multiple bars simultaneously is performed, then productivity increases, but heat dissipation becomes insufficient leading to reduced lapping quality
Solution Approach 1:
The lubricant composition is designed to perform multiple functions simultaneously: it provides lubrication for material removal, acts as a heat transfer medium for thermal management, and repels swarf particles through electronegativity. This multi-functionality allows the same composition to support lapping of multiple bars simultaneously while maintaining both productivity and heat dissipation effectiveness
Solution Approach 2:
The lubricant composition maintains continuous cooling and lubrication action during the lapping process by being applied continuously to the lapping interface. This continuous action ensures that even when multiple bars are lapped simultaneously, heat is constantly dissipated and lubrication is maintained throughout the process, preventing temperature buildup and maintaining lapping quality
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 lubricant composition effectively repels swarf and improves heat dissipation, allowing for increased lapping of multiple bars without significant swarf buildup, reducing surface scratching and extending lapping plate life, while avoiding the need for silica.
Implementation Method 1
lubricating the interface between any abrasive materials and the surface of the one or more bars being lapped
Implementation Method 2
removing heat from the one or more bars during lapping
Implementation Method 3
materials like PTFE to enhance electronegative properties and prevent swarf adherence
Data Source
AI summary
Disclosed herein are embodiments of a method of making a lubricant composition for lapping a ceramic material. The method includes mixing a base lubricant component and a powdered wax composition component to form the lubricant composition. The powdered wax composition component includes a powdered wax dispersion or a powdered wax emulsion. The amount of powdered wax composition component mixed with the base lubricant component is from 0.01 to 10 percent by weight of the lubricant composition. Also disclosed herein are embodiments of related lubricant compositions and/or methods of using the lubricant to lap a ceramic substrate (e.g., one or more bars of sliders).