Lapping Plate Temperature Control for Slider Precision
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Solution Overview
Problem
Lapping processes for sliders in data storage systems face challenges due to unintended temperature variations, which can lead to inaccurate material removal and dimensional issues, affecting the performance of transducer elements in hard disk drives.
Innovation Solution
A lapping system with a temperature control mechanism that regulates the lapping plate's temperature to a target value, using a combination of cooling and heating systems, to maintain precise temperature control during the lapping process, thereby minimizing the impact of thermal expansion and contraction on the sliders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the lapping plate temperature is not controlled during the lapping process, then the lapping operation can proceed without additional temperature control equipment, but unintended temperature variations cause inaccurate material removal and dimensional issues affecting transducer element performance
Solution Approach 1:
The temperature control system pre-cools or pre-heats the lapping plate to a target temperature before the lapping process begins. This preliminary temperature stabilization prevents thermal expansion and contraction of the lapping plate during operation, ensuring accurate material removal and dimensional control of slider elements from the start of the process.
Solution Approach 2:
A thermal intermediary system (temperature control apparatus) is introduced between the heat generation source (lapping friction) and the lapping plate. This intermediary actively manages heat transfer by circulating coolant or heating fluid through the lapping plate, mediating the thermal effects to maintain dimensional stability and measurement accuracy.
2Reliability
If the lapping plate temperature is controlled to a target temperature, then thermal expansion and contraction effects on slider elements are minimized, but the system requires additional temperature control equipment and operational complexity
Solution Approach 1:
The temperature control system incorporates temperature sensors that continuously monitor the lapping plate temperature and feed this information back to a controller. The controller adjusts the heating or cooling rate based on the measured temperature, maintaining the lapping plate at a target temperature within specified tolerances. This closed-loop feedback ensures dimensional stability of slider elements while automating the temperature control process.
Solution Approach 2:
The system dynamically changes the thermal parameters (temperature, heating rate, cooling rate) of the lapping plate based on process requirements and measured conditions. By adjusting these parameters in real-time, the system maintains optimal dimensional stability for different slider materials and lapping conditions without requiring overly complex mechanical modifications.
3Productivity
If temperature variations occur during lapping, then the lapping process can proceed without temperature control, but slider elements experience undue recession or expansion affecting critical drive parameters like fly height and areal density
Solution Approach 1:
The system performs preliminary temperature stabilization of the lapping plate before engaging the lapping process. By pre-cooling or pre-heating the lapping plate to the target temperature, the system eliminates thermal transients that would otherwise cause dimensional drift in slider elements during lapping, ensuring consistent fly height and areal density from the first part processed.
Solution Approach 2:
The temperature control system provides beforehand cushioning against thermal effects by maintaining the lapping plate at a stable target temperature throughout the lapping process. This preemptive thermal management cushions the slider elements from thermal expansion and contraction forces, protecting critical dimensions and drive parameters from variation without slowing down the lapping operation.
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 ensures accurate material removal and reduces the risk of undue recession or expansion of slider elements, maintaining critical drive parameters like fly height and areal density by maintaining consistent temperature tolerances, allowing for flexible temperature settings across different specifications and hardware variations.
Implementation Method 1
controlling the temperature of the lapping plate to a target temperature during at least a portion of the lapping
Implementation Method 2
using a combination of cooling and heating systems
Implementation Method 3
minimizing the impact of thermal expansion and contraction on the sliders
Data Source
AI summary
The present disclosure includes a lapping system that includes a temperature control system system to heat or cool the lapping plate while lapping. The temperature control system can include a closed circuit fluid system and/or one or more electrical resistive heating elements. In some embodiments that cooling system can control the temperature of the lapping plate during lapping to within +/−5° C., or even +/−0.5° C.