U.S. patent application number 11/063805 was filed with the patent office on 2005-06-30 for texturing of magnetic disk substrates.
Invention is credited to Homola, Andrew.
Application Number | 20050142990 11/063805 |
Document ID | / |
Family ID | 32229838 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050142990 |
Kind Code |
A1 |
Homola, Andrew |
June 30, 2005 |
Texturing of magnetic disk substrates
Abstract
A method for texturing a substrate for a magnetic disk comprises
abrading the substrate using nano-sized diamond particles (e.g.
having a diameter less than or equal to 20 nm). A magnetic layer is
then deposited over the substrate. Even when the texture is
extremely smooth (e.g. less than about 2.2 .ANG. Ra), the disk
still exhibits good Hc and MrT orientation ratios, SNR and
PW50.
Inventors: |
Homola, Andrew; (Morgan
Hill, CA) |
Correspondence
Address: |
Law Offices of Kenneth E. Leeds
P.O. Box 2819
Sunnyvale
CA
94087-0819
US
|
Family ID: |
32229838 |
Appl. No.: |
11/063805 |
Filed: |
February 23, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11063805 |
Feb 23, 2005 |
|
|
|
10299028 |
Nov 18, 2002 |
|
|
|
Current U.S.
Class: |
451/63 ;
G9B/5.299 |
Current CPC
Class: |
G11B 5/8404
20130101 |
Class at
Publication: |
451/063 |
International
Class: |
B24B 001/00 |
Claims
1-28. (canceled)
29. A method comprising texturing a substrate with particles having
a size less than or equal to about 20 nm to texture said substrate,
said texturing resulting in a Ra of said substrate less than 2.2
.ANG..
30. Method of claim 29 wherein said particles comprise diamond.
31. Method of claim 29 further comprising forming a magnetic layer
above said substrate.
32. Method of claim 31 further comprising forming one or more
intermediate layers between said substrate and said magnetic
layer.
33. Method of claim 32 wherein said abrasive particles have a
diameter greater than or equal to 2 nm.
34. Method of claim 32 wherein said texture causes said magnetic
layer to exhibit anisotropic magnetic characteristics.
35. Method of claim 32 further comprising mounting said substrate
with said magnetic layer formed thereon in a disk drive.
36. A method comprising texturing a magnetic data storage medium
substrate with particles being sufficiently small to form a texture
Ra less than 2.2 .ANG. while inducing magnetic anisotropy in a
magnetic layer deposited over said substrate, said texturing
resulting in a Ra of said substrate less than 2.2 .ANG..
37. Method of claim 36 further comprising depositing said magnetic
layer over said substrate.
38. Method of claim 37 further comprising one or more intermediate
layers between said substrate and said magnetic layer.
39. Method of claim 38 further comprising mounting said substrate
with said magnetic layer formed thereon in a disk drive.
40. Structure comprising: a substrate textured with abrasive
particles having a size less than or equal to about 20 nm and
having a Ra less than 2.2 angstroms.
41. Structure of claim 40 further comprising a magnetic recording
layer formed above said substrate, said magnetic recording layer
exhibiting anisotropy.
42. Structure of claim 41 further comprising one or more
intermediate layers formed between said substrate and said magnetic
layer.
43. A magnetic disk drive comprising the structure of claim 41.
44. A magnetic data storage medium substrate textured with abrasive
particles sufficiently small to leave a Ra less than 2.2 angstroms
while permitting a magnetic layer deposited over said substrate to
exhibit magnetic anisotropy.
45. Structure of claim 44 further comprising a magnetic layer
formed over said substrate, said layer exhibiting magnetic
anisotropy.
46. Structure of claim 45 further comprising one or more
intermediate layers formed between said substrate and said magnetic
layer.
Description
BACKGROUND OF THE INVENTION
[0001] This invention pertains to methods for texturing magnetic
disk substrates and the resulting substrates. This invention also
pertains to methods for manufacturing magnetic data storage media
and the resulting media.
[0002] Magnetic disks (e.g. disk 1 of FIG. 1) are manufactured by
a) polishing a substrate; b) texturing the substrate; and c)
depositing a set of layers on the substrate, e.g. by sputtering or
other vacuum deposition technique. The substrate typically
comprises an aluminum alloy 2 coated with an electroless-plated
nickel phosphorus ("NiP") alloy 3. The layers can comprise one or
more seed and/or underlayers 4 (e.g. Cr or a Cr alloy underlayer),
one or more magnetic layers 5 (e.g. a Co alloy layer), and one or
more protective overcoats 6 (e.g. one or more carbon protective
overcoat layers). The texture typically comprises scratches in the
circumferential direction (or generally in the circumferential
direction) formed using polycrystalline or mionocrystalline diamond
particles having a size of about 0.05 to 0.5 .mu.m in diameter. The
texture typically accomplishes several functions, including
facilitating the flying of a read-write held above the magnetic
disk. However, more importantly, the texture causes the magnetic
characteristics of the disk to become anisotropic. For example, the
coercivity Hc of the magnetic layer is higher in the
circumferential direction than the radial direction. Also, the
magnetic remanence Mr is higher in the circumferential direction
than the radial direction.
[0003] It has been a trend in magnetic disk manufacturing that
disks have been getting smoother and smoother. This is in part
because it is necessary to permit the read-write head to fly closer
and closer to the magnetic layer. Current disks have a Ra of about
3 to 5 .ANG. as measured by an atomic force microscope ("AFM"). (Ra
is a well-known measure of roughness.) Unfortunately, as disks
become smoother, and as the Ra drops below 5 .ANG., the magnetic
anisotropy of the disk drops. Further, other magnetic
characteristics of the disk are degraded, e.g. the signal to noise
ratio ("SNR") and the pulse width PW50.
[0004] In prior art diamond texturing, the diamond particles of
texturing slurries have highly variable sizes. Because of this, the
resulting texture scratches have highly variable sizes (i.e.
variable widths and depths). This, in turn, can cause a) magnetic
defects (e.g. because the effective flying height between the
read-write head and magnetic layer increases at locations where the
texture scratches are too deep); and b) reliability problems caused
by the fact that deep scratches can make it difficult to passivate
the disk. Further, the presence of oversized particles in the
texturing slurry results in poor glide characteristics because
excessively high ridges can be formed adjacent excessively deep
scratches.
SUMMARY
[0005] During a method in accordance with the present invention,
"nano-sized" particles are used to texture a substrate. The
particles are typically diamond, and typically have a diameter less
than about 20 nm. In one embodiment, the particle diameters are
less than about 10 nm. The particle diameters are typically greater
than about 1 nm, and in one embodiment greater than about 2 nm. In
one embodiment, they are between 3 and 8 nm. (The word "diameter"
as used herein does not require that the particles are spherical.)
The particles are typically monocrystalline. In one embodiment,
they are used to form scratch lines having a density greater than
50 lines per micron.
[0006] After texturing, one or more layers are deposited on the
substrate, including a magnetic alloy layer (e.g. a Co or Fe based
alloy layer) to thereby form a magnetic data storage medium.
[0007] We have discovered that by using "nano-sized particles"
(e.g. nano-sized diamond particles) for texturing a magnetic disk
we can form extremely smooth textures without sacrificing such
magnetic characteristics as anisotropy, SNR and FW50.
[0008] In one embodiment, the slurry has generally uniform particle
sizes (e.g. between 3 and 8 nm). Because of this, the texture lines
formed by the slurry will have uniform widths and depths. This is
important because it is desirable to avoid gouges (e.g. to avoid
magnetic defect and passivation problems discussed above) and to
avoid forming high ridges (e.g. to thereby avoid glide height
problems). Further, the nano-sized diamond particles also result in
a reduction of large low frequency texture lines. Also, the scratch
size and density of scratch lines help one to control the magnetic
layer grain size. (It is desirable to form a magnetic layer
comprising small uniform grain sizes.)
[0009] In one embodiment, the nano-sized particles are free
abrasive particles, e.g. within a liquid (for example an aqueous
slurry). In another embodiment, the nano-sized particles are fixed
abrasive particles, e.g. bound to an abrasive cloth or other
structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 schematically illustrates in cross section a prior
art magnetic disk.
[0011] FIGS. 2A and 2B schematically illustrate in plan view and
cross-section apparatus for texturing a magnetic disk
substrate.
[0012] FIG. 3 illustrates the relationship between MrT OR (the MrT
orientation ratio) vs. roughness Ra for disks comprising substrates
textured with conventional diamond particles and nano-sized diamond
particles. FIG. 3 also illustrates the relationship between SNR and
roughness Ra for disks comprising substrates textured with
conventional diamond particles and nano-sized diamond
particles.
[0013] FIGS. 4A, 4B and 4C are SEM photographs of prior art diamond
texturing particles.
[0014] FIGS. 5A and 5B are SEM photographs of nano-sized diamond
particles used during a method in accordance with the present
invention.
[0015] FIG. 6A is an AFM photograph of a first substrate textured
using prior art diamond texturing particles.
[0016] FIG. 6B is a cross section AFM scan of the substrate of FIG.
6A.
[0017] FIG. 6A' is an AFM photograph of a second substrate textured
using prior art diamond texturing particles.
[0018] FIG. 6B' is a cross section AFM scan of the substrate of
FIG. 6A'.
[0019] FIG. 7A is an AFM photograph of a substrate textured using
nano-sized diamond texturing particles.
[0020] FIG. 7B is a cross section AFM scan of the substrate of FIG.
6A.
[0021] FIG. 8 illustrates a magnetic disk drive comprising a disk
formed using a method in accordance with our invention.
DETAILED DESCRIPTION
[0022] FIGS. 2A and 2B illustrate apparatus 11 for texturing a
substrate 12. (Apparatus 11 is not novel in and of itself.) In
FIGS. 2A and 2B, a motor (not shown) rotates substrate 12 while a
sheet 13 of material (typically nylon) is pushed against substrate
12. (Sheet 13 moves off of a supply reel 14, around a roller 15,
and onto a take-up reel 16 (see arrow B).) Roller 15 urges sheet 13
against substrate 12, e.g. with a force between 1 and 10 pounds. In
one embodiment, the force is between 2.5 and 5 pounds. A slurry
comprising nano-sized diamond particles (described below) is
introduced between sheet 13 and substrate 12. Simultaneously, sheet
13 and roller 15 reciprocate, moving back and forth in a direction
A. (Alternatively, substrate 12 can reciprocate instead of sheet 13
and roller 15.) The diamond particles form texture scratches that
are non-random, and are in a generally circumferential direction in
substrate 12. Because of the motion of sheet 13 and roller 15 in
the direction of arrow A, the resulting texture exhibits a
cross-hatch. (The texture lines therefore intersect, e.g. at an
angle between 0 and 20 degrees, and in one embodiment a range of 2
to 6 degrees, although these values are merely exemplary.) In one
embodiment, apparatus 11 is device model no. 1800, available from
EDC Corporation located in California. The slurry flow rate is
typically between 0.1 and 1 ml/second. The above-described
apparatus and parameters are merely exemplary. Other types of
texturing apparatus and parameters can also be used.
[0023] In one embodiment, the slurry comprises a commercial coolant
or lubricant and between 0.4 to 1 gram/liter of diamond particles,
e.g. about 0.4 grams per liter of diamond particles. As mentioned
above, the diamond particles can have a diameter from 2 to 8
nm.
[0024] As mentioned above, the size and spacing of the texture
marks depend at least in part on the size of the diamond particles.
Using particles having sizes greater than or equal to 2 nm helps
ensure a certain minimum grain size in the subsequently formed
magnetic layer. (if the grains are too small, their magnetization
state may be thermally unstable. However, in other embodiments,
diamond particles less than 2 nm in size can be used.)
[0025] Description of Types of Nano-Diamond Particles Used With the
Invention
[0026] In one embodiment, the particles can be formed using a
method as described by Vereschagin et al. in U.S. Pat. No.
5,861,349, incorporated herein by reference. Such particles are
available from Ultradiamond Technologies, Inc. of Somerville, Mass.
(e.g. product no. UD90). Alternatively, the particles can be of the
type available from PlasmaChem of Mainz, Germany. They are
typically formed at a high temperature and pressure with an
explosion. In one embodiment, the diamond particles comprise about
90% or more of diamond, with some ash and/or oxidatable carbon
making up the remainder.
[0027] Manufacture of a Magnetic Disk Comprising a Substrate
Textured Using the Present Invention
[0028] After texturing, one of more underlayers, magnetic layers
and protective overcoats are applied to the disk. In one
embodiment, the underlayers and magnetic layers can be as described
in U.S. patent application Ser. No. 10/075,123, filed by Bertero et
al. and incorporated herein by reference or U.S. Pat. No.
6,150,015, issued to Bertero at al. and also incorporated herein by
reference. The overcoat layers can be as described in U.S. patent
application Ser. No. 09/604,490, filed by Lairson et al. or German
patent document DE 101 30 942 A1, each being incorporated herein by
reference. However, the specific processes described by Bertero and
Lairson are merely exemplary, and other processes could also be
used. For example, other disk manufacturing processes in which one
or more ferromagnetic layers (e.g. Co or Fe based magnetic layers)
are deposited by a vacuum deposition process (e.g. sputtering) can
be used. Also, other types of layers can be deposited on the
substrate during the disk manufacturing process.
[0029] Properties of a Magnetic Disk Using a Substrate Textured
With Nano-Diamond Particles
[0030] A magnetic disk manufactured using nano-sized diamond
particles exhibits several surprising and unique characteristics.
As mentioned above, prior to the present invention, substrates were
textured using diamond particles having a diameter between 0.05 and
0.5 .mu.m. FIG. 3 illustrates the relationship between the MrT
orientation ratio (MrT OR) for disks comprising substrates
manufactured using such particles. (MrT equals magnetic remanence
times thickness of the magnetic layer.) Curve 22 shows the MrT OR
for disks manufactured using diamond particles in accordance with
the prior art, whereas curve 24 shows the MrT OR for disks
manufactured using nano-sized diamond particles (in this case
having diameters between 3 and 8 nm with an average diameter of 5
nm). As can be seen, when using the prior art texturing particles
(curve 22), MrT OR dropped precipitously when the Ra dropped below
about 2.2 .ANG.. Thus, one skilled in the art, using these
particles, would be led to believe that one could not use a Ra less
than 2.2 .ANG. without sacrificing MrT OR. However, as demonstrated
in curve 24, we have discovered that when using nano-sized diamond
particles, one can maintain MrT OR high (e.g. about 1.6) even for
Ra's of 1.4 to 1.5 .ANG.. This is an important and surprising
discovery.
[0031] FIG. 3 also shows that for a magnetic disk textured with the
prior art diamond particles, when the Ra dropped below 2.2 .ANG.,
the SNR dropped precipitously. (See curve 26.) Surprisingly, when
one textures the substrates with nano-sized diamond particles, even
at a Ra of about 1.4 to 1.5 .ANG., the SNR remained high--about
0.45 dB. (See curve 28.) Again, this result was completely
unexpected.
[0032] FIGS. 4A, 4B and 4C are SEM photographs of prior art diamond
texturing particles at 60,000 .times., 300,000 .times. and 500,000
.times. magnification, respectively, whereas FIGS. 5A and 5B are
SEM photographs of nano-sized diamond texturing particles used
during a texturing method in accordance with the invention at
magnifications of 60,000 and 500,000 .times., respectively. As can
be seen, the prior art particles are larger than the nano-sized
particles. Further, there is considerable size variation in the
prior art particles, and the prior art particles have numerous
jagged and irregular facets. This leads to highly variable and
undesirable scratch characteristics.
[0033] As mentioned above, FIGS. 5A and 5B are SEM photographs of
nano-sized diamond particles used to texture magnetic disks in
accordance with the present invention. As can be seen, the
particles are small, have roughly the same size. As discussed
above, the small size and uniformity of particles permits one to
form small, uniform scratch marks.
[0034] FIGS. 6A and 6A' are AFM photographs of first and second
substrates textured using prior art diamond particles. FIGS. 6B and
6B' are AFM cross section scans of the substrates of FIGS. 6A and
6A', respectively. FIGS. 7A and 7B are an AFM photograph and cross
section scan, respectively, of a substrate textured using
nano-sized diamond particles. Table 1 below lists various
parameters relating to the surface finish of the substrates of
FIGS. 6. 6' and 7.
1TABLE I (Distances in angstroms) Distance between Distance between
mean surface mean surface Substrate AFM Ra and peaks and valleys
3.9 16.8 32.0 FIG. 6A', 6B' 2.8 14.9 23.9 1.6 8.2 13.2
[0035] As can be seen, the scratch lines of the substrate of FIGS.
7A and 7B are shallower and more regular compared to the scratch
lines of FIGS. 6A, 6B, 6A' and 6B'. As mentioned above, this has
the following advantages: a) the effective flying height of a
read-write head with respect to the magnetic layer is reduced; b)
there are fewer or no deep gouges for causing magnetic defects; c)
the substrate of FIGS. 7A and 7B is easier to passivate; d) there
are fewer or no ridges for a read-write head to collide with; and
e) the texture grooves of FIGS. 7A and 7B facilitate forming
smaller magnetic grains.
[0036] In one embodiment, the texture scratch lines formed using a
method in accordance with the invention have a density greater than
or equal to 50 per micron and less than or equal to 150 per micron.
In one embodiment, the scratch density is between about 50 and 120
per micron, e.g. about 80 per micron. (Typically, the minimum
scratch density is inversely proportional to the particle diameter,
whereas the maximum scratch density is inversely proportional to
{fraction (1/10)} of the particle diameter.)
INDUSTRIAL APPLICATION
[0037] Magnetic disks are incorporated into disk drives, e.g. disk
drive 30 of FIG. 8. Referring to FIG. 8, disk 32 is mounted on a
spindle 33, which is rotated by a motor 34. A pair of read-write
heads 35a, 35b are held on suspensions 36a, 36b, which in turn are
mounted on an actuator 38 for moving heads 35a, 35b over the
various tracks of disk 32. During use, heads 35a, 35b "fly" above
disk 32, and are used to read data from or write data to disk 32.
(It will be appreciated that both sides of disk 32 are textured,
and the various layers used to manufacture a magnetic disk are
formed on both sides of disk 32, although in other embodiments, one
can texture and deposit these layers on only one side of disk
32.)
[0038] While the invention has been described with respect to
specific embodiments, those skilled in the art will appreciate that
changes can be made in form and detail without departing from the
spirit and scope of the invention. For example, different types of
substrates can be textured using the above-described techniques.
Thus, the substrate can be an aluminum alloy disk coated with a
nickel phosphorus alloy. However, materials other than NiP and
aluminum alloys can be used (e.g. glass or glass ceramic
substrates), and substrate shapes other than disks can be used
(e.g. for media that is not disk-shaped). Different types of
texturing apparatuses, with different parameters, can also be used.
Different sized particles (e.g. having a size from 0.5 to 20 nm)
can be used.
[0039] While the method of the present invention can be used to
manufacture disks used in longitudinal magnetic recording, the
method can also be used to form disks used in vertical recording.
(As mentioned above, controlling the scratch sizes can be used to
control or influence the magnetic layer grain size. This is useful
in both longitudinal and vertical recording.) The method of the
present invention can also be used to form isotropic media. While
the texturing particles are typically diamond, other hard materials
can also be used. Accordingly, all such changes come within the
invention.
* * * * *