Staggered Grinding Material for Thick Portions Without Collapse
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Solution Overview
Problem
Conventional grinding materials face issues with increased aspect ratio leading to grinding portion collapse and warpage, reducing their lifespan and grinding efficiency.
Innovation Solution
The grinding portions are arranged in a staggered manner with controlled thickness ratios to prevent collapse and warpage, using a flexible base and specific abrasive grains to maintain grinding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the height of the grinding portion is increased to extend the lifetime of the grinding material, then the lifetime is improved, but the aspect ratio of the grinding portion is increased causing the grinding portion to collapse during grinding
Solution Approach 1:
The invention transitions from a single-layer grinding structure to a multi-layer structure with a base layer and a grinding layer. This dimensional change allows the grinding portion height to be increased while the base layer provides support to prevent collapse, thus extending lifetime without compromising stability.
Solution Approach 2:
The invention uses a composite structure consisting of a base layer and a grinding layer with abrasive grains and binder. This composite material approach allows optimization of each layer's properties - the base layer provides structural support while the grinding layer provides grinding functionality, resolving the contradiction between height increase and collapse prevention.
2Stability of the object's composition
If the aspect ratio of the grinding portion is reduced to prevent collapse, then the stability is improved, but the area of each grinding portion is increased causing warpage of the base during printing or hardening
Solution Approach 1:
The invention segments the grinding layer into multiple smaller grinding portions separated by grooves. This segmentation reduces the area of each individual grinding portion, preventing warpage of the base during printing and hardening, while maintaining stability through the staggered arrangement and controlled aspect ratio.
Solution Approach 2:
The invention applies different properties to different regions: the grinding portions have high hardness and abrasive content for grinding stability, while the grooves provide spacing to reduce warpage. This local quality differentiation allows each region to optimize its function without causing overall structural issues.
3Shape
If the thickness of the base is increased to reduce warpage, then the shape stability is improved, but the flexibility and ductility of the base decrease making it difficult to follow the surface shape of the workpiece
Solution Approach 1:
The invention optimizes the base thickness to a specific range (0.5-3.0mm) that balances flatness and flexibility. This parameter change allows the base to have sufficient thickness to reduce warpage while maintaining enough flexibility to follow the workpiece surface, resolving the contradiction between shape stability and adaptability.
4Shape
If the thickness of the base is increased to reduce warpage, then the shape stability is improved, but the grinding rate decreases due to reduced flexibility
Solution Approach 1:
The invention optimizes the base thickness parameter to a specific range (0.5-3.0mm) that maintains sufficient flexibility for high grinding rate while providing enough thickness to reduce warpage. This parameter optimization resolves the contradiction between shape stability and productivity.
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 configuration allows for increased thickness of grinding portions without reducing grinding rate, extending the material's lifespan and preventing base warpage.
Implementation Method 1
a grinding material containing fixed abrasive grains is used for processing a glass substrate
Data Source
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AI summary
An object of the present invention is to provide a grinding material in which grinding portions can be increased in thickness while a decrease in grinding rate is inhibited. The grinding material according to the present invention includes a base, and a grinding layer overlaid on a front face side of the base and containing abrasive grains and a binder. The grinding layer includes a plurality of columnar grinding portions. The plurality of the grinding portions are configured so that the grinding portions are arranged in a staggered manner. The average thickness of the grinding portions is no less than 300 µm. The area of a top face of each of the grinding portions is no less than 6 mm2. The average thickness of the base is no less than 300 µm and no greater than 3,000 µm.