Helical Write Coil with Magnetic Connection Studs
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Solution Overview
Problem
The manufacturing of helical write coils for perpendicular magnetic recording is complex and costly due to the need for constructing coil layers in dimensions perpendicular to the deposited layers, increasing manufacturing complexity and cost.
Innovation Solution
A write head structure with a helical write coil where upper and lower coil portions are electrically connected by magnetic, conductive connection studs made of NiFe, allowing these studs to be constructed in the same steps as other magnetic structures, simplifying the manufacturing process by eliminating additional steps required for non-magnetic studs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-magnetic connection studs are used to electrically connect upper and lower coil portions, then electrical conductivity is achieved, but manufacturing complexity and cost increase due to additional manufacturing steps
Solution Approach 1:
The connection studs are merged with the magnetic structures (write pole, return pole, or magnetic shield) by making them co-formed from the same magnetic material. This eliminates the need for separate non-magnetic stud components and their associated manufacturing steps, while maintaining electrical connectivity through the magnetic material itself
Solution Approach 2:
The magnetic structures serve dual functions: they provide magnetic flux conduction for the write head operation and simultaneously serve as electrical connection elements (connection studs) to connect the upper and lower coil portions. This multi-functionality eliminates the need for dedicated connection studs
2Reliability
If non-magnetic connection studs are used to electrically connect upper and lower coil portions, then electrical conductivity is achieved, but manufacturing cost increases due to additional manufacturing steps
Solution Approach 1:
The connection studs are merged with the magnetic structures (write pole, return pole, or magnetic shield) by making them co-formed from the same magnetic material. This eliminates the need for separate non-magnetic stud components and their associated manufacturing steps, while maintaining electrical connectivity through the magnetic material itself
Solution Approach 2:
The magnetic structures serve dual functions: they provide magnetic flux conduction for the write head operation and simultaneously serve as electrical connection elements (connection studs) to connect the upper and lower coil portions. This multi-functionality eliminates the need for dedicated connection studs
3Reliability
If helical coil structure is implemented for perpendicular magnetic recording, then writing performance is improved, but manufacturing complexity increases due to construction in perpendicular dimensions
Solution Approach 1:
The helical coil structure is integrated with the magnetic structures through co-formed connection studs, merging the coil assembly process with the magnetic structure fabrication process. This eliminates the need for separate assembly steps to attach connection studs to the coils
Solution Approach 2:
The connection studs are formed as integral parts of the magnetic structures before the coil deposition process. This preliminary formation of connection studs allows subsequent coil layers to be deposited directly connected to them, simplifying the overall manufacturing sequence
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 significantly reduces manufacturing complexity and cost by integrating connection studs with existing magnetic structures, reducing the number of manufacturing operations and cycle time by approximately 30 operations and 22 hours, while maintaining performance.
Implementation Method 1
Current conducted to the coil layer induces a magnetic flux in the pole pieces which causes a magnetic field to fringe out at a write gap at the ABS
Implementation Method 2
the connection studs are constructed of a magnetic, electrically conductive material such as NiFe
Data Source
AI summary
A magnetic write head for perpendicular magnetic recording that has a helical coil design that reduces manufacturing complexity and increases cycle time for manufacture. The write head includes a write pole and a helical write coil having upper coil portions that pass above the write pole and lower coil portions that pass below the write pole. The upper and lower coil portions are connected with another by connection studs. Whereas the upper and lower coil portions are constructed of a non-magnetic, electrically conductive material such as Cu, the connection studs are constructed of a magnetic, electrically conductive material such as NiFe. By constructing the connection studs of a magnetic material, they can be constructed in the same manufacturing steps used to manufacture various magnetic structures of the write head, such as a magnetic shaping layer and/or the back gap. This greatly simplifies the manufacture of the write head by eliminating many additional manufacturing steps that would otherwise be required to manufacture a helical coil having non-magnetic connection studs.