Magnetic Head Substructure Indicators for Track Width Precision
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Solution Overview
Problem
In the manufacturing of magnetic heads for perpendicular magnetic recording systems, it is challenging to accurately achieve a reduced track width, which leads to issues such as adjacent track erasing and unwanted writing due to skew, and existing methods like frame plating struggle to form grooves with small widths, resulting in inaccurate neck height determination and inefficient manufacturing processes.
Innovation Solution
A method involving the formation of a magnetic head substructure with indicators to accurately locate the medium facing surfaces, allowing for precise alignment and separation of pre-head portions, and the use of conductive indicators connected to pole layers to prevent charge accumulation and ensure accurate imaging during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If frame plating is used to form the pole layer, then the manufacturing process is simplified, but the groove width cannot be reduced sufficiently leading to inaccurate track width
Solution Approach 1:
The manufacturing process is divided into two independent stages: first forming the pole layer by frame plating, then separately forming the groove by etching. This segmentation allows each process to be optimized independently - frame plating for ease of manufacture and etching for precision groove width control
Solution Approach 2:
The pole layer is formed in advance by frame plating before the groove is formed. This preliminary action establishes the magnetic pole structure first, then the groove is precisely etched afterward, allowing both processes to contribute their strengths without interfering with each other
2Reliability
If the neck height is reduced to improve overwrite property, then writing characteristics improve, but the manufacturing precision becomes harder to control
Solution Approach 1:
A spacer layer is introduced as an intermediary element between the pole layer and the groove formation process. This spacer layer serves as a physical template that defines the groove width and neck height, making the dimensional control independent of the frame plating process variations and enabling precise control of the neck height for improved overwrite property
3Manufacturing precision
If indicators are added to the substructure for precise alignment, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The indicators on the substructure serve as self-aligning references that guide the positioning of the pole layer and groove during manufacturing. These indicators are inherently part of the substructure and automatically provide alignment information, eliminating the need for separate alignment mechanisms or complex positioning systems
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 enables accurate determination of the track width and neck height, preventing skew-related issues and improving manufacturing efficiency by ensuring precise alignment and reducing the risk of errors in the magnetic head's write characteristics.
Implementation Method 1
the use of conductive indicators connected to pole layers to prevent charge accumulation and ensure accurate imaging during manufacturing
Data Source
AI summary
A method of manufacturing magnetic heads comprises the step of: fabricating a magnetic head substructure by forming a plurality of components of the magnetic heads on a single substrate, wherein a plurality of rows of pre-head portions that will be the respective magnetic heads later are aligned in the substructure; and fabricating the magnetic heads by separating the pre-head portions from one another through cutting the substructure. In the step of fabricating the substructure, a plurality of indicators are formed, each of the indicators serving as a reference for indicating the location of a region ABS in which the medium facing surfaces of the magnetic heads are to be formed.