Solid Resin Lapping Plate Coating for Ceramic Slider Uniformity
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Solution Overview
Problem
Existing lapping plate technologies face challenges in achieving uniform and durable abrasive coatings for effectively abrading ceramic sliders, particularly due to the limitations of two-part liquid epoxy systems which introduce non-uniformities and require multiple steps, leading to incomplete curing and reduced lapping efficiency.
Innovation Solution
A method involving a solid resin powder and abrasive particles applied in a single step with an aqueous carrier, where the carrier is evaporated and the resin is cured to form a robust abrasive coating on a platen, allowing for improved uniformity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two-part liquid epoxy systems are used for abrasive coating, then the coating can be applied, but the coating uniformity deteriorates and manufacturing complexity increases
Solution Approach 1:
The patent changes the physical state of the resin from liquid to solid powder form. This parameter change eliminates the mixing and viscosity control issues associated with liquid epoxy systems, resulting in more uniform coating application and simplified manufacturing process while maintaining effective abrasive coating formation after curing
Solution Approach 2:
The patent extracts the liquid carrier from the coating system by using solid resin powder instead. This eliminates the need for multiple-component mixing and solvent management, reducing manufacturing complexity while achieving uniform abrasive coating through direct application and curing of the solid powder mixture
2Productivity
If liquid epoxy coatings are used, then the coating can be formed, but the curing completeness worsens and lapping efficiency decreases
Solution Approach 1:
Changing the resin from liquid to solid powder form fundamentally alters the curing behavior. The solid powder system provides more complete and reliable curing without the degradation issues seen in liquid systems, directly improving lapping efficiency through better coating integrity and consistency
3Ease of manufacture
If multiple application steps are used for liquid epoxy, then coating can be achieved, but manufacturing time increases and process simplicity is reduced
Solution Approach 1:
The patent merges multiple coating steps into a single application process by using solid resin powder that can be applied and cured in one operation. This eliminates the sequential mixing, application, and curing steps required for liquid epoxy systems, significantly reducing manufacturing cycle time while improving process simplicity
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 approach results in a more uniform and durable abrasive coating that enhances lapping efficiency by reducing stripe height sigma and bar crown inflation, while maintaining consistent lap rates, as demonstrated by comparisons with traditional liquid epoxy-based coatings.
Implementation Method 1
b) evaporating the aqueous carrier
Implementation Method 2
c) substantially curing the solid resin powder to form an abrasive coating comprising the solid abrasive particles and the cured resin
Data Source
AI summary
The present disclosure involves a method of making a lapping plate by coating a platen with solid resin powder, abrasive particles, and an aqueous carrier followed by evaporating the aqueous carrier and curing the solid resin powder to form an abrasive coating. The present disclosure also involves related lapping plates.