Actuator Tilt Interposer for Magnetic Head Lapping Precision
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Solution Overview
Problem
In hard disk drive manufacturing, achieving precise control of magnetic core width and alignment between read and write elements is challenging due to inherent variations in thin-film processes, leading to suboptimal areal density and performance.
Innovation Solution
A lapping tool assembly with flexible wedge angle and stripe height flexures allows for independent and variable control of each head slider within a row-bar, enabling precise lapping to target wedge angles and stripe heights, reducing manufacturing variations and improving alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional lapping processes are used, then manufacturing simplicity is maintained, but manufacturing precision of magnetic core width and alignment deteriorates due to inherent process variations
Solution Approach 1:
The lapping tool assembly is segmented into multiple independent actuation mechanisms, each controlling a separate lapping element. This allows individual adjustment of each lapping element's position and orientation, enabling precise control of magnetic core width and alignment for different regions of the head slider without requiring a completely complex monolithic system.
Solution Approach 2:
The lapping tool assembly incorporates dynamic adjustment capabilities where actuation mechanisms can modify the position and orientation of lapping elements during the lapping process. This dynamic control allows real-time compensation for variations in the lapping process, improving manufacturing precision without permanently complicating the base tool structure.
2Manufacturing precision
If independent control of each head slider is implemented, then manufacturing precision of wedge angle and stripe height improves, but device complexity of the lapping tool increases
Solution Approach 1:
The actuation mechanisms in the lapping tool assembly are designed with multi-functionality, where each mechanism can perform multiple functions such as positioning, orienting, and applying force to the lapping elements. This universal design reduces the total number of separate mechanisms needed, thereby improving manufacturing precision without proportionally increasing device complexity.
Solution Approach 2:
The lapping tool assembly utilizes parameter changes in the actuation mechanisms, allowing continuous adjustment of position, orientation, and force parameters. This enables precise control of wedge angle and stripe height through controlled parameter variations rather than requiring complex discrete adjustment mechanisms for each parameter.
3Manufacturing precision
If precise lapping control is applied, then alignment between read and write elements improves, but manufacturing time and process complexity increase
Solution Approach 1:
The lapping tool assembly is configured to perform preliminary alignment and positioning of lapping elements before the actual lapping process begins. This preliminary action ensures that precise alignment between read and write elements is achieved from the start, reducing the need for iterative adjustments and thereby decreasing total manufacturing time despite the enhanced precision capabilities.
Data Source
AI summary
A lapping tool assembly includes a mount tool and an interposer structure interposed between actuators and the mount tool, where the interposer includes interposer pins reactively coupled with the actuators such that each interposer pin is configured to receive a translational force from a corresponding actuator and to transmit the force to a corresponding actuation pin of the mount tool. The interposer may include a zero z-axis shift flexure system, and/or a z-axis decoupling flexure system, and/or alignment features, for accurately transmitting the actuation forces to the mount tool, while inhibiting affecting other portions of the mount tool.