Coated carrier for lapping and methods of making and using

A method of lapping comprising:

• (a) providing a double-sided lapping machine having two opposed lapping surfaces or a single-sided lapping machine;
• (b) providing the carrier of any of the above claims comprising a base carrier having a first major surface, a second major surface and at least one aperture for holding a workpiece, said aperture extending from the first major surface through the base carrier to the second major surface, wherein the circumference of said aperture is defined by a third surface of the base carrier, and further wherein at least a portion of the first major surface or at least a portion of each of the first and the second major surfaces comprises a polymeric region, said polymeric region comprising at least the following adhesion promoting layers:
• (1) a primer layer, wherein the primer layer comprises at least one of a phenolic resin or a novolac resin;
• (2) a tie layer adjoining the primer layer, wherein the tie layer comprises at least one of an amino-functional epoxy resin or a hydroxyl-functional epoxy resin;
• and
• (3) a polymeric layer adjoining the tie layer on a side opposite the primer layer, wherein the polymeric layer comprises an isocyanate-functional polymer;
• (c) providing a workpiece;
• (d) inserting the workpiece into the aperture;
• (e) inserting the carrier into the lapping machine;
• (f) providing relative motion between the workpiece and the lapping surface while maintaining contact between the lapping surface and the workpiece;
• and
• (g) removing at least a portion of the workpiece.

A method of making a coated lapping carrier comprising:

• (a) providing a base carrier having a first major surface, a second major surface and at least one aperture for holding a workpiece, said aperture extending from the first major surface through the base carrier to the second major surface, wherein the circumference of said aperture is defined by a third surface of the base carrier;
• (b) applying a primer layer to at least one surface of the base carrier, wherein the primer layer comprises at least one of a phenolic resin or a novolac resin;
• (c) applying a tie layer adjoining the primer layer, wherein the tie layer comprises at least one of an amino-functional epoxy resin or a hydroxyl-functional epoxy resin;
• and
• (d) applying a polymeric layer adjoining the tie layer, wherein the polymeric layer comprises an isocyanate-functional polymer.