Slider Trailing Edge Topography via Sacrificial Overcoat
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Solution Overview
Problem
The existing methods for forming sliders in hard disk drives face challenges in creating a robust protective head overcoat that effectively protects the air bearing surface during manufacturing and operation, particularly in maintaining the final trailing edge topography and preventing contamination.
Innovation Solution
A method involving the application of a sacrificial protective head overcoat followed by patterning and removal, followed by the application of a final protective head overcoat, which includes multiple layers and adhesion layers to ensure protection and uniformity of the air bearing surface, utilizing techniques like ion milling and chemical vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protective head overcoat is applied to the air bearing surface, then protection against contamination is improved, but the final trailing edge topography may be compromised during manufacturing
Solution Approach 1:
The sacrificial protective head overcoat is applied to the air bearing surface before patterning to provide protection during manufacturing. This preliminary protective action prevents contamination during subsequent processing steps while allowing the final topography to be formed through controlled removal of the sacrificial layer and application of the final overcoat.
Solution Approach 2:
The protective head overcoat is divided into two functional segments: a sacrificial protective layer applied initially to protect during manufacturing, and a final protective layer applied after patterning to provide long-term protection. This segmentation allows each layer to serve its specific purpose without interfering with the other.
2Reliability
If multiple protective head overcoat layers are applied, then protection and uniformity are improved, but manufacturing complexity increases
Solution Approach 1:
The protective head overcoat is segmented into a sacrificial layer and a final protective layer, each with distinct functions. The sacrificial layer is removed after patterning, allowing the final layer to be applied directly to the patterned surface. This segmentation provides robust protection while maintaining manageable manufacturing complexity through standardized deposition and removal processes.
3Manufacturing precision
If the sacrificial protective head overcoat is removed after patterning, then the final trailing edge topography is exposed, but the air bearing surface becomes vulnerable during the process
Solution Approach 1:
The sacrificial protective head overcoat is applied to the air bearing surface before patterning to provide protection during the vulnerable exposure period. This preliminary protective action ensures the surface remains protected until the final protective layer is applied after patterning is complete.
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 the formation of a robust and uniform protective head overcoat that maintains the final trailing edge topography and prevents contamination, enhancing the operational reliability and longevity of the sliders.
Implementation Method 1
applying a sacrificial protective head overcoat to cover the air bearing surface
Implementation Method 2
a first milling to remove material from each slider in a lapping direction
Data Source
AI summary
The present disclosure includes methods of using a sacrificial, protective head overcoat during the manufacture of sliders. In some embodiments, the final trailing edge topography of the transducer devices is formed before applying the sacrificial, protective head overcoat. In some embodiments, the final trailing edge topography of the transducer devices is formed after removing the sacrificial, protective head overcoat.