LED Light Heat Treatment for Magnetic Recording Medium Bonding
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Solution Overview
Problem
Existing methods for manufacturing magnetic recording media face challenges in achieving stable bonding between the protective film and the lubricant layer due to ozone generation during light irradiation treatments.
Innovation Solution
A method involving the successive lamination of a magnetic layer, a protective film, and a lubricant layer on a nonmagnetic substrate, followed by a heat treatment using an LED light source with a center wavelength shorter than 500 nm, excluding the 170 nm to 190 nm wavelength range, to prevent ozone generation and enhance bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultraviolet light irradiation treatment is performed to increase bonding strength of the lubricant layer, then bonding strength is improved, but ozone is generated which decomposes lubricant molecules and reduces reliability
Solution Approach 1:
The patent changes the wavelength parameter of the light source from ultraviolet (which generates ozone) to visible light range (405 nm or longer), specifically excluding the 170-190 nm wavelength that causes ozone generation. This parameter change maintains the bonding strength improvement while preventing lubricant decomposition.
Solution Approach 2:
The patent converts the harmful effect of light irradiation (ozone generation) into a beneficial process by selecting specific wavelengths that provide the desired bonding strength enhancement without causing ozone-related decomposition. The light treatment becomes beneficial without the harmful side effects.
2Strength
If ultraviolet lamp is used for heat treatment, then bonding strength is improved, but the light spreads to surroundings and decomposes oxygen into ozone
Solution Approach 1:
The patent changes the wavelength parameter to 405 nm or longer (visible light range), which does not have sufficient energy to decompose oxygen into ozone. This eliminates the harmful side effect while maintaining the heat treatment and bonding strength improvement benefits.
3Strength
If conventional heat treatment methods are used, then bonding strength is improved, but the process is time-consuming and reduces productivity
Solution Approach 1:
The patent replaces conventional thermal heat treatment (heating apparatus) with optical energy from LED light sources. This substitution enables faster energy transfer and reduces treatment time while achieving the same or better bonding strength, thereby improving productivity.
Solution Approach 2:
The patent uses LED light sources that can be rapidly switched on and off, enabling precise control of treatment duration. This allows for optimized treatment cycles that achieve bonding strength improvement in shorter time compared to conventional continuous heating methods.
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 effectively prevents ozone generation, thereby stabilizing the bonding strength between the protective film and the lubricant layer, and allows for a faster and more efficient heat treatment process, reducing manufacturing costs and increasing productivity.
Implementation Method 1
performing a heat treatment a surface of the lubricant layer by irradiation of light from an LED light source
Implementation Method 2
performing a heat treatment a surface of the lubricant layer by irradiation of light
Implementation Method 3
the light of the ultraviolet lamp will decompose oxygen and generate the ozone
Data Source
AI summary
A method for manufacturing a magnetic recording medium includes successively laminating at least a magnetic layer, a protective film, and a lubricant layer on a nonmagnetic substrate, and performing a heat treatment a surface of the lubricant layer by irradiation of light from an LED light source.