Tech Tip: How to Install Convoluted Wafer Brushes

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Convoluted wafer brushes have a distinctive wavy design, with the inner part of the wafer featuring a convoluted shape. Unlike traditional flat wafers that require spacers, these brushes eliminate the need for additional components, making installation quicker and more efficient. Let’s dive into the process of installing convoluted wafer brushes.

Types of Wafer Racks

There are two types of wafer racks: the 3-bar rack and the 4-bar rack. Each convoluted wafer includes two pins inside its ring that straddle the rack bars to hold the wafer securely in place. The wavy design, with high and low points around the center ring, requires proper alignment for correct spacing during installation.

Installing on a 3-Bar Wafer Rack

The 3-bar rack is typically used for smaller ID cores, such as the 6 ⅜” or 8” wafer families.

Step 1: Place the first wafer on the rack so that the pins on the high convolute rest over the first bar at the 12:00 position.
Step 2: Flip the second wafer upside down, aligning the pins on the lower convolute. Rotate it 120 degrees to the next bar, positioning the pins at 4:00.
Step 3: Return the third wafer to the high convolute position. Rotate it 120 degrees to the next bar, with the pins at 8:00.

Repeat this pattern until the core is fully assembled.

Installing on a 4-Bar Wafer Rack

The 4-bar rack is designed for larger 10” ID cores, such as 10”x27”, 10”x32”, and 10”x36” wafers.

Step 1: Place the first wafer with the pins on the high convolute over the first bar at the 12:00 position.
Step 2: Flip the second wafer upside down and rotate it 180 degrees to the opposite bar, placing the pins at 6:00.
Step 3: Align the next wafer with the first, rotating 180 degrees to return the pins to 12:00.

Repeat this process until the core is complete.

Download the PDF to see examples of 3-bar and 4-bar Wafer Racks.

Download a PDF of the Pro-tip