Lapping carrier and method of using the same

Abstract

A lapping carrier includes a base having first and second opposed major surfaces and at least one aperture extending from the first major surface to the second major surface. A wear layer is disposed on the first major surface of the base. The wear layer includes an outer polymer layer comprising at least one of polyether ether ketone or ultrahigh molecular weight polyethylene, and a first adhesive layer disposed between the outer polymer layer and the base

1 . A lapping carrier comprising:
 a base having first and second opposed major surfaces and at least one aperture extending from the first major surface to the second major surface; and   a first wear layer disposed on the first major surface of the base, the wear layer comprising:
 a first outer polymer layer secured to the base, wherein the first outer polymer layer has a first exposed major surface, and wherein the first outer polymer layer comprises at least one of polyether ether ketone or ultrahigh molecular weight polyethylene; and 
 a first adhesive layer disposed between the first outer polymer layer and the base. 
   
     
     
         2 . The lapping carrier of  claim 1 , wherein the first outer polymer layer comprises polyether ether ketone. 
     
     
         3 . The lapping carrier of  claim 1 , wherein the first outer polymer layer comprises ultrahigh molecular weight polyethylene. 
     
     
         4 . The lapping carrier of  claim 1 , further comprising a first base adhesion promoting layer, disposed between the first adhesive layer and the first major surface of the base, wherein the first base adhesion promoting layer is selected from the group consisting of plasma treatments, polymeric primers, silane coupling agents, and combinations thereof. 
     
     
         5 . The lapping carrier of  claim 1 , further comprising a first polymer adhesion promoting layer disposed between the first adhesive layer and the first outer polymer layer, wherein the first polymer adhesion promoting layer is selected from the group consisting of plasma treatments, polymeric primers, and combinations thereof. 
     
     
         6 . The lapping carrier of  claim 1 , wherein the first adhesive layer comprises a pressure-sensitive adhesive. 
     
     
         7 . The lapping carrier of  claim 1 , further comprising:
 a second wear layer disposed on the second major surface of the base, the wear layer comprising:
 a second outer polymer layer secured to the base, wherein the second outer polymer layer has a second exposed major surface, and wherein the second outer polymer layer comprises at least one of polyether ether ketone or ultrahigh molecular weight polyethylene; and 
 a second adhesive layer disposed between the first outer polymer layer and the base. 
   
     
     
         8 . The lapping carrier of  claim 7 , wherein the second outer polymer layer comprises polyether ether ketone. 
     
     
         9 . The lapping carrier of  claim 7 , wherein the second outer polymer layer comprises ultrahigh molecular weight polyethylene. 
     
     
         10 . The lapping carrier of  claim 7 , further comprising a second base adhesion promoting layer, disposed between the second adhesive layer and the second major surface of the base, wherein the second base adhesion promoting layer is selected from the group consisting of plasma treatments, polymeric primers, silane coupling agents, and combinations thereof. 
     
     
         11 . The lapping carrier of  claim 7 , further comprising a second polymer adhesion promoting layer disposed between the second adhesive layer and the second outer polymer layer, wherein the second polymer adhesion promoting layer is selected from the group consisting of plasma treatments, polymeric primers, and combinations thereof. 
     
     
         12 . The lapping carrier of  claim 7 , wherein the second adhesive layer comprises a pressure-sensitive adhesive. 
     
     
         13 . The lapping carrier of  claim 1 , wherein the base comprises a steel. 
     
     
         14 . The lapping carrier of  claim 1 , wherein the lapping carrier has a maximum thickness of less than 975 microns. 
     
     
         15 . A method of lapping comprising:
 placing a workpiece in the at least one aperture of a lapping carrier according to  claim 1 ;   placing the lapping carrier into a lapping machine having at least one lapping surface; and   providing relative motion between the workpiece and the at least one lapping surface thereby abrading the workpiece.   
     
     
         16 . The method of  claim 15 , further comprising providing a working fluid at the interface between the workpiece and the at least one lapping surface. 
     
     
         17 . The method of  claim 16 , wherein the working fluid comprises water. 
     
     
         18 . The method of  claim 15 , wherein the at least one lapping surface comprises a three-dimensional, textured, fixed-abrasive article.