Magnetic Recording Medium Lubrication With LED-Based Contaminant Removal
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Solution Overview
Problem
Existing magnetic recording medium production methods face challenges in efficiently removing foreign matter and contaminants from the surface, leading to reduced lubricating layer coverage and increased production complexity due to solvent use in lubricant removal processes.
Innovation Solution
A magnetic recording medium production method involving the application of a first and second lubricant, followed by surface burnishing with an abrasive, and the removal of the second lubricant using LED light irradiation, which gasifies and separates contaminants without solvent residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent is used to remove the first lubricant, then the lubricant can be removed from the surface, but solvent residue and foreign matter are generated leading to reduced lubricating layer coverage
Solution Approach 1:
The patent changes the removal method from chemical (solvent-based) to physical (LED light irradiation). The LED light source with specific wavelength (less than 500 nm, excluding 170-190 nm range) provides energy that selectively removes the second lubricant through photolysis or photoevaporation, avoiding solvent residue and foreign matter generation while maintaining lubricating layer coverage
Solution Approach 2:
The patent replaces the chemical solvent-based removal system with an optical field-based removal system. Instead of using solvents to dissolve and remove lubricants, the invention uses LED light irradiation to selectively remove the second lubricant, eliminating the harmful effects of solvent residue and simplifying the production process
2Manufacturing precision
If tape burnishing is performed after lubricating layer formation, then scratches are prevented on the protective layer surface, but the process complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated process. The LED light irradiation step serves dual purposes: it removes the second lubricant and simultaneously gasifies and separates contaminants from the surface. This merging of removal and cleaning functions into a single step simplifies the production process while maintaining surface quality
Solution Approach 2:
The patent extracts and eliminates the need for separate solvent removal and contamination cleaning steps. By using LED light irradiation, the invention simultaneously removes the second lubricant and gasifies contaminants in a single operation, reducing process complexity while maintaining manufacturing precision
3Reliability
If conventional UV irradiation is used to remove lubricant, then the lubricant can be removed, but ozone is generated causing environmental pollution and safety issues
Solution Approach 1:
The patent changes the wavelength parameter of the irradiation light source. Instead of using conventional UV light (170-190 nm) that generates ozone, the invention specifies LED light with a center wavelength of less than 500 nm, explicitly excluding the 170-190 nm range. This parameter change eliminates ozone generation while maintaining effective lubricant removal through photolysis or photoevaporation mechanisms
Solution Approach 2:
The patent converts the potentially harmful effect of UV irradiation (ozone generation) into a beneficial process by selecting specific LED wavelengths that provide sufficient energy for lubricant removal without triggering ozone formation. The LED light source with optimized wavelength range achieves effective removal while eliminating the harmful byproduct
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 method effectively reduces foreign matter, enhances lubricating layer coverage, simplifies the production process, and maintains high recording density and durability of the magnetic recording medium.
Implementation Method 1
irradiating the stack, to which the first lubricant and the second lubricant are applied, with light emitted from an LED light source
Implementation Method 2
the removal of the second lubricant includes irradiating the stack, to which the first lubricant and the second lubricant are applied, with light emitted from an LED light source
Implementation Method 3
the burnishing includes abrading the surface of the stack by pressing a tape containing the abrasive against the surface of the stack
Data Source
AI summary
A magnetic recording medium production method, which includes forming a lubricating layer over a stack including a substrate, a magnetic recording layer over the substrate, and a protective layer over the magnetic recording layer, includes applying a first lubricant and a second lubricant to the stack; burnishing, with an abrasive, a surface of the stack to which the first lubricant and the second lubricant are applied; and removing the second lubricant over the stack. The burnishing includes abrading the surface of the stack by pressing a tape containing the abrasive against the surface of the stack. The removal of the second lubricant includes irradiating the stack, to which the first lubricant and the second lubricant are applied, with light emitted from an LED light source.