Diamond-Like Carbon Layer Adhesion on Slider Air Bearing Surface
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Solution Overview
Problem
Existing methods for forming a diamond-like carbon (DLC) layer on the air bearing surface (ABS) of a slider in disk drive devices face challenges in achieving strong adhesion while minimizing the layer's thickness, leading to issues with corrosion resistance and flying height optimization.
Innovation Solution
A method involving the formation of a mixing layer by depositing a first DLC layer on the ABS, removing it to expose the mixing layer, and then applying a second DLC layer, which enhances adhesion and reduces the overall thickness of the DLC layer, using techniques like chemical vapor deposition or ion beam deposition with controlled ion beam angles and energies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a DLC layer is directly deposited on the ABS to reduce thickness, then the flying height is reduced and storage capacity is improved, but the adhesion ability is insufficient and the layer is easily peeled off
Solution Approach 1:
The patent applies preliminary action by forming a mixing layer through ion beam treatment before depositing the final DLC layer. The ion beam modifies the ABS surface in advance, creating a roughened and chemically activated surface that enhances adhesion. This preliminary surface preparation ensures that when the thin DLC layer is subsequently deposited, it adheres strongly despite the reduced thickness, resolving the contradiction between thinness and adhesion.
Solution Approach 2:
The patent utilizes parameter changes by controlling the ion beam energy and angle during the mixing layer formation process. By adjusting these parameters, the surface morphology and chemical composition of the ABS are optimized to maximize adhesion. The ion beam parameters are specifically tuned to create a mixing layer with enhanced bonding characteristics, allowing the DLC layer to adhere strongly even at reduced thickness, thus resolving the adhesion-thickness contradiction.
2Reliability
If a silicon layer is deposited before the DLC layer to improve adhesion, then the adhesion ability is enhanced, but the total thickness increases and flying height cannot be further reduced
Solution Approach 1:
The patent uses an intermediary approach by creating a mixing layer through ion beam treatment that serves as an adhesion promoter between the ABS and DLC layer. This mixing layer acts as a mediator with intermediate properties - it is chemically bonded to the ABS and provides strong nucleation sites for DLC deposition. This intermediary layer is much thinner than a conventional silicon layer but achieves comparable or superior adhesion, thus resolving the contradiction between adhesion enhancement and thickness minimization.
Solution Approach 2:
The patent applies parameter changes by controlling the ion beam energy (typically 50-500 eV) and incidence angle (typically 30-60 degrees) to create a mixing layer with optimal adhesion properties. By adjusting these parameters, the mixing layer achieves sufficient thickness for strong bonding while remaining much thinner than alternative adhesion layers like silicon. This parameter optimization allows the system to achieve strong adhesion without the thickness penalty of conventional approaches.
3Productivity
If the DLC layer thickness is reduced to improve storage capacity, then the flying height is reduced and storage capacity is improved, but the corrosion resistance may be compromised
Solution Approach 1:
The patent applies preliminary action by using ion beam treatment to create a mixing layer that enhances the protective function of the subsequent thin DLC layer. The ion beam modifies the ABS surface to provide better mechanical interlocking and chemical bonding, which compensates for the reduced thickness of the DLC layer. This preliminary surface preparation ensures that even a thin DLC layer can provide adequate corrosion resistance, thus resolving the contradiction between thinness (for storage capacity) and protection (for corrosion resistance).
Solution Approach 2:
The patent creates a composite structure consisting of the ABS substrate, the ion-modified mixing layer, and the DLC coating. This composite structure leverages the strengths of each component: the ABS provides the base substrate, the ion-modified mixing layer provides enhanced adhesion and corrosion barrier properties, and the thin DLC layer provides chemical inertness and low friction. The synergistic combination of these layers achieves both thin overall thickness (for storage capacity) and adequate corrosion resistance.
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 approach results in a DLC layer with improved adhesion to the ABS, maintaining corrosion resistance while reducing the flying height and minimizing the risk of delamination, thus enhancing the storage capacity and reliability of disk drive devices.
Implementation Method 1
forming a mixing layer in the ABS of the slider by depositing a first DLC layer on the ABS
Implementation Method 2
depositing a first DLC layer on the ABS
Implementation Method 3
removing the first DLC layer to make the mixing layer exposed
Implementation Method 4
forming a second DLC layer on the mixing layer
Data Source
AI summary
A method for forming a diamond-like carbon (DLC) layer on air bearing surface (ABS) of a slider, comprises steps of: providing sliders arranged in arrays, each slider having an ABS; forming a mixing layer in the ABS of the slider by depositing a first DLC layer on the ABS, the mixing layer consisting of the slider material and the first DLC layer material; removing the first DLC layer to make the mixing layer exposed; forming a second DLC layer on the mixing layer.