Phase-Change Lapping Carrier for HDD Slider Bars
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Solution Overview
Problem
The existing lapping process for slider bars in hard disc drive systems requires multiple carrier changes due to different adhesion and rigidity needs for rough and kiss lapping steps, increasing time, effort, and cost.
Innovation Solution
A carrier tool with a mounting structure that changes its shear modulus from a high to a low state in response to an external stimulus, allowing the same carrier to be used for both rough and kiss lapping steps, eliminating the need for multiple carrier changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid carrier is used for rough lapping, then good adhesion and resistance to twisting are achieved, but the carrier cannot provide conformal mounting for kiss lapping
Solution Approach 1:
The mounting structure transitions from a rigid state during rough lapping to a compliant state during kiss lapping. This is achieved through a phase-change material that alters its mechanical properties in response to temperature changes, enabling the same structure to provide both rigid support and conformal mounting as needed
Solution Approach 2:
The mounting structure's physical state is changed by applying thermal energy. During rough lapping, the material is in a rigid phase providing strong adhesion. During kiss lapping, thermal energy induces a phase change to a compliant state that allows conformal mounting, thus changing the parameter of rigidity to adaptability
2Reliability
If different carriers are used for rough and kiss lapping, then optimal performance for each step is achieved, but process time and cost increase
Solution Approach 1:
A single mounting structure is designed to perform multiple functions: providing rigid support during rough lapping and conformal mounting during kiss lapping. This multi-functionality eliminates the need for separate carriers for each lapping step, reducing process time and complexity while maintaining lapping quality
Solution Approach 2:
The functions of two separate carriers (rigid support carrier and conformal mounting carrier) are merged into a single mounting structure that can transition between states. This consolidation eliminates the need for carrier changes and transfers, reducing time and operational complexity
3Manufacturing precision
If multiple carrier changes are implemented, then optimal lapping conditions for each step are met, but device complexity and cost increase
Solution Approach 1:
The mounting structure dynamically adjusts its mechanical properties through phase change in response to thermal stimulation. This allows one structure to replace multiple static structures, simplifying the overall device while maintaining the ability to provide optimal conditions for different lapping steps
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 solution enables efficient and cost-effective lapping by maintaining precise control over slider bar dimensions and reducing the complexity of multiple mounting and bonding steps, thereby improving the manufacturing process for hard disc drive sliders.
Implementation Method 1
The carrier has a mounting structure comprising a material configured to have a first modulus of at least 1,000,000 Pa at a first period of time and a second modulus of 500 Pa to 500,000 Pa at a second period of time subsequent to the first period. The change from the first modulus to the second modulus is due to an external stimulus on the material.
Data Source
AI summary
A carrier for a slider row bar for a lapping process. The carrier has a mounting structure comprising a material configured to have a first modulus of at least 1,000,000 Pa at a first period of time and a second modulus of 500 Pa to 500,000 Pa at a second period of time subsequent to the first period. The change from the first modulus to the second modulus is due to an external stimulus on the material.