HK1168464B - Systems and methods for repositioning row bars used for manufacturing magnetic heads - Google Patents

Description

System and method for repositioning row bars for manufacturing magnetic heads

Technical Field

The present invention relates to magnetic recording technology, and more particularly to a system and method for repositioning or changing the orientation of row bars used in the manufacture of magnetic heads.

Background

Information storage devices, such as magnetic disk drives, use magnetic media to store data and a movable slider having a read/write head positioned over the magnetic media to selectively read and write data to the magnetic media. The slider can be formed by processing a wafer, which is typically used to manufacture sliders, using a series of processes. First, the wafer may be subjected to a lap joint process, a cleaning process, a deposition process, and an etching process. The processed wafer may then be diced by a suitable dicing tool, such as a diamond cutting wheel, into a plurality of row bars, each of which will ultimately be diced into a plurality of sliders. Each row bar may then be subjected to a series of subsequent processes, such as lapping, photolithography, bonding, and testing. Each row bar is then cut into individual sliders using a cutter such as the diamond cutting wheel described above.

Many of the process steps described above require loading and transferring row bars, can be time consuming and inefficient, as these steps are often performed by an operator using tweezers. For example, manual transfer of row bars from one pallet to another with a 90 degree change in row bar direction takes time and runs into processing defects, cross contamination, and out of order row bar position in the pallet slots. The 90 degree transfer is typically performed at manufacturing stages such as bar division, side lapping, Diamond Like Carbon (DLC) coating, end debonding, and slider separation. Various ways of repositioning row bars during slider manufacturing processes have been proposed. However, existing approaches often require complex joining steps and can be quite time consuming. As a result, there is a need for improved systems and methods for repositioning row bars during slider manufacturing processes.

Disclosure of Invention

Aspects of the present invention relate to systems and methods for repositioning or changing the orientation of row bars used in the manufacture of magnetic heads.

In one embodiment, the present invention is directed to a system for changing the direction of a plurality of row bars used in the manufacture of a magnetic head, the system comprising: a base support, comprising: a top surface; and at least one support arm positioned on the top surface and configured to rotate relative to the top surface from a first position to a second position; a tray assembly coupled to the illuminating a support arm, the tray assembly comprising: a first tray assembly comprising a plurality of first channels, each channel configured to hold one of the row bars in an initial position; a transfer substrate including a plurality of transfer channels, each transfer channel configured to receive one of the row bars from the first tray as the support arm moves from the first position to the second position; and a second tray including a plurality of second passages, each configured to receive one of the row bars from the transfer substrate and to hold the one of the row bars in a final position, wherein the first tray and the second tray are configured to sandwich the transfer substrate therebetween, wherein the row bar in the final position is rotated from the initial position by a predetermined angle.

In another embodiment, the invention is directed to a method for changing the direction of a plurality of row bars for manufacturing a magnetic head, the method comprising: positioning each of the plurality of row bars into one of a plurality of lanes of the first tray, wherein each of the plurality of lanes is configured to hold one of the row bars in an initial position; positioning a transfer substrate including a plurality of transfer channels on a first tray such that the first channels and the transfer channels are aligned, wherein each transfer channel of the transfer substrate is configured to receive one of the row bars from the first tray; positioning a second tray comprising a plurality of second channels on the transfer substrate such that the transfer channels and the second channels are aligned, wherein each second channel is configured to receive one of the row bars from the transfer substrate and to hold the one of the row bars in a final position; attaching a first tray, a transfer substrate, and a second tray to at least one support arm to form an assembly, the at least one support arm positioned on a top surface of the base support and configured to rotate relative to the top surface from a first position to a second position; and moving the assembly from the first position to the second position, thereby moving the plurality of row bars from the initial position to the final position, wherein the row bars in the final position are rotated from the initial position by a predetermined angle.

Drawings

FIG. 1a is a perspective view of a row bar repositioning assembly including a tray assembly coupled to a rotational support arm attached to a base support in a first position according to one embodiment of the present invention;

FIG. 1b is a cross-sectional view of a portion of the tray assembly of FIG. 1a, taken along A-A, illustrating a plurality of row bars in a vertical position, according to one embodiment of the present invention;

FIG. 2a is a perspective view of the row bar repositioning assembly of FIG. 1a with the tray assembly in an intermediate position according to one embodiment of the present invention;

FIG. 2b is a cross-sectional view of the same portion of the tray assembly of FIG. 2a taken along A-A with the tray assembly in the intermediate position shown in FIG. 2a, illustrating the row bar in the intermediate position according to one embodiment of the present invention;

FIG. 3a is a perspective view of the row bar repositioning assembly of FIG. 1a with the tray assembly in a second position, according to one embodiment of the present invention;

FIG. 3b is a cross-sectional view of the same portion of the tray assembly of FIG. 3a taken along A-A with the tray assembly in the second position shown in FIG. 2a illustrating the row bar in a horizontal position according to one embodiment of the present invention;

fig. 4 is a perspective cutaway view of a portion of the tray assembly of fig. 1 a-3 a, illustrating row bars in an initial vertical position, an intermediate position, and a final horizontal position, according to one embodiment of the present invention.

FIG. 5 is a perspective view of a vertical tray of the tray assembly of FIGS. 1 a-3 a, including a plurality of channels for holding row bars in an initial position, according to one embodiment of the present invention.

Fig. 6 is a perspective view of a transfer tray of the tray assembly of fig. 1 a-3 a, including a plurality of transfer channels for changing the direction of the row bars as the tray assembly rotates, according to one embodiment of the present invention.

FIG. 7 is a perspective view of a horizontal tray of the tray assembly of FIGS. 1 a-3 a, including a plurality of channels for receiving and maintaining row bars in a final horizontal position, according to one embodiment of the present invention.

Fig. 8 is an exploded perspective view of the tray assembly and base support of the row bar repositioning assembly of fig. 1 in a first position, according to one embodiment of the present invention.

Fig. 9 is an exploded perspective view of the tray assembly and base support of the row bar repositioning assembly of fig. 1 in a second position, according to one embodiment of the present invention.

Fig. 10 is an exploded perspective view of a tray assembly of the row bar repositioning assembly of fig. 1, according to one embodiment of the invention. And

FIG. 11 is a flow diagram of a process of operating a row bar relocation component according to one embodiment of the present invention.

Detailed Description

Referring now to the drawings, embodiments of a system and method for repositioning or changing the orientation of row bars used in the manufacture of magnetic heads are illustrated. In various embodiments, the system includes a rowbar repositioning assembly having a base support and a tray assembly attached to one or more support arms configured to rotate about an axis parallel to a top surface of the base support. The tray assembly may include a vertical tray, a transfer tray, and a horizontal tray. A vertical tray or first tray may be used to hold the row bar in a vertical position relative to the top surface of the base support. The transfer tray or transfer substrate receives row bars from the vertical tray and repositions the row bars as the tray assembly rotates. The horizontal tray or second tray receives the row bar from the transfer tray and holds the row bar in a horizontal position as the tray assembly is further rotated to a final position. In the final position, the row bar has been rotated about 90 degrees from the initial vertical orientation to the final horizontal orientation. The tray assembly can be rotated in the opposite direction so that the row bars are horizontal in the initial position and vertical in the final position. In various embodiments, the row bar is rotated about 90 degrees. In other embodiments, the row bar is rotated by other preselected angles.

Fig. 1a is a perspective view of a row bar repositioning assembly 100 including a tray assembly 102 coupled to a rotating support arm 104 attached to a base support 106 in a first position according to one embodiment of the present invention. The tray assembly 102 includes a horizontal tray 108 positioned on top of a transfer tray 110. The transfer tray is positioned on top of the vertical tray 112. The vertical tray is positioned on top of the bottom pusher tray 114.

FIG. 1b is a cross-sectional view of a portion of the tray assembly 102 of FIG. 1a, taken along A-A, illustrating a plurality of row bars 116 in a vertical position, according to one embodiment of the present invention. The vertical tray 112 includes a plurality of vertical channels 118 for maintaining the row bar 116 in a vertical position when the tray assembly 102 is in a first position along the base support 106. In the first position, the transfer tray 110 is positioned on top of the vertical tray 112. The transfer tray 110 includes a plurality of transfer channels 120 aligned with the vertical channels 118 to receive the row bar 116 as the tray assembly 102 rotates. The transfer channels 120 each include a small opening at one end and a large opening at the other end wherein the large opening is offset from the small opening in a lateral position to facilitate rotation of the row bar along the longitudinal axis as the tray assembly is selected.

As illustrated in fig. 1a, in the first position of the tray assembly 102, the horizontal tray 208 is located at the bottom of the transfer tray 110. The horizontal tray 108 includes a plurality of horizontal channels 122 aligned with the transfer channels 120 to receive the row bars 116 from the transfer tray 110 as the tray assembly 102 rotates. The horizontal tray 108 and horizontal channel 122 are configured to maintain the row bar in a horizontal position when the tray assembly 102 is fully rotated to the second position (see fig. 3 a).

Returning to fig. 1a, the swivel support arm 104 is attached to a cylindrical shaft 124 that is guided and held by two shaft holders 126. Two shaft retainers 126 are spaced apart and attached to the top surface of the base support 106. Each shaft retainer 126 includes a circular opening for receiving a portion of the cylindrical shaft 124. In some embodiments, only one shaft retainer is used. In one embodiment, other coupling and selection assemblies as known in the art may be used to allow the tray assembly 102 to rotate on a semicircular path above the top surface of the base support 106. The tray assembly 102 is attached to the support arm 104 using upper and lower clamps 128, 130 (see fig. 2a) and various other attachment features known in the art.

FIG. 2a is a perspective view of the row bar repositioning assembly 100 of FIG. 1a with the tray assembly 102 in an intermediate position, according to one embodiment of the present invention. In the intermediate position, i.e., about 90 degrees clockwise from the first position of the tray assembly, the row bar 116 may begin to move from the vertical tray 112 to the transfer tray 110.

FIG. 2b is a cross-sectional view of the same portion of the tray assembly 102 of FIG. 2a taken along A-A, with the tray assembly 102 in the intermediate position shown in FIG. 2a, illustrating the row bar 116 in the intermediate position, according to one embodiment of the present invention. Although fig. 2a and 2b show the tray assembly 102 in an intermediate position during operation of the row bar repositioning assembly, the tray assembly will generally not stop at the intermediate position.

FIG. 3a is a perspective view of the row bar repositioning assembly 100 of FIG. 1a with the tray assembly 102 in a second position, according to one embodiment of the present invention. In the second position, which is about 90 degrees clockwise from the first position of the tray assembly, gravity and/or rotational force applied to the tray assembly moves the row bar 116 from the vertical tray 112 through the transfer tray 110 to the horizontal tray 108.

FIG. 3b is a cross-sectional view of the same portion of the tray assembly 102 of FIG. 3a taken along A-A, with the tray assembly 102 in the second position shown in FIG. 2a, illustrating the row bar 116 in a horizontal position, according to one embodiment of the present invention.

Fig. 4 is a perspective cutaway view of a portion of the tray assembly 102 of fig. 1 a-3 a, illustrating the row bars 116 in an initial vertical position, an intermediate position, and a final horizontal position, according to one embodiment of the present invention.

FIG. 5 is a perspective view of the vertical tray 112 of the tray assembly 102 of FIGS. 1 a-3 a, including a vertical channel 118 for holding the row bar 116 in an initial position, according to one embodiment of the present invention.

Fig. 6 is a perspective view of the transfer tray 110 of the tray assembly 102 of fig. 1 a-3 a, including a plurality of transfer channels 120 for changing the direction of the row bars 116 as the tray assembly 102 rotates, according to one embodiment of the present invention. The transfer tray 110 includes a frame 130 and two opposing transfer substrate inserts 132 secured to the frame 130 using a plurality of screws 134. The frame 130 and the transfer substrate insert 132 include mounting holes for aligning or guiding the sheath 136. The alignment sheath 136 may extend into holes in the vertical and horizontal trays to ensure proper alignment of the channels for each tray assembly component.

Fig. 7 is a perspective view of the horizontal tray 108 of the tray assembly 102 of fig. 1 a-3 a, including a horizontal channel 122 for receiving and maintaining the row bar 116 in a final horizontal position, according to one embodiment of the present invention. The horizontal tray 108 in fig. 7 is depicted with a plurality of row bars 116 resting in a horizontal position.

Fig. 8 is an exploded perspective view of the tray assembly 102 and the base support 106 of the row bar repositioning assembly 100 of fig. 1 in a first position, according to one embodiment of the present invention. The base pusher 114 has a plurality of protrusions that can be used to push the row bar in adhesion to the vertical tray 112. In some embodiments, the base pusher 114 is not used and is not part of the tray assembly 102.

In one embodiment, the vertical tray 112 and the transfer tray 110 each have a length and width of about 4 inches and a thickness of about 0.2 inches. In one embodiment, the horizontal tray 108 has a length and width of about 4 inches and a thickness of about 0.3 inches. In one embodiment, the base support 106 has a length of about 12 inches, a width of about 5 inches, and a thickness of about 1 inch. In one embodiment, the vertical tray, the horizontal tray, and the transfer substrate insert are made of an electrostatic discharge safe plastic. In one embodiment, the base support is made of aluminum and the frame of the transfer tray is made of stainless steel. In other embodiments, other suitable dimensions and materials may be used for each component of the row bar repositioning assembly.

Fig. 9 is an exploded perspective view of the tray assembly 102 and the base support 106 of the row bar repositioning assembly 100 of fig. 1 in a second position, according to one embodiment of the present invention.

Fig. 10 is an exploded perspective view of the tray assembly 102 of the row bar repositioning assembly 100 of fig. 1, according to one embodiment of the present invention.

FIG. 11 is a flow diagram of a process 200 for operating a row bar relocation component in accordance with one embodiment of the present invention. In various embodiments, the process may be performed by an operator during a manufacturing process to produce the slider. In the first block, the process positions (202) each row bar in one of the lanes of a first tray, such as a vertical tray, where each lane is configured to hold the row bar in an initial position. In one embodiment, the initial position is a vertical position such that the longer of the two dimensions of the cross-section of the row bar is perpendicular to the top surface of the vertical tray. The process then positions (204) a transfer substrate including a plurality of transfer lanes on the first tray such that the first lanes and transfer lanes are aligned, wherein each transfer lane is configured to receive one of the row bars from the first tray. In various embodiments, alignment is assisted with a guide sheath extending from the transfer substrate.

The process then positions (206) a second tray including a plurality of second lanes on the transfer substrate such that the transfer lanes and the second lanes are aligned, wherein each second lane is configured to receive one of the row bars from the transfer substrate and to hold the row bar in a final position. In various embodiments, alignment is again aided by a guide sheath extending from the transfer substrate. The process then attaches (208) the first tray, the transfer substrate, and the second tray to the at least one support arm to form a tray assembly, wherein the support is positioned on a top surface of the base support and is configured to rotate relative to the top surface from a first position to a second position.

The process then moves (210) the tray assembly from the first position to the second position, thereby moving the plurality of row bars from the initial position to the final position, wherein the row bars in the final position are rotated from the initial position by a predetermined angle. In various embodiments, the first position represents a zero degree position of the support arm along the top surface of the base support, and the second position represents a 180 degree position of the support arm along the top surface of the base support. In various embodiments, the predetermined angle is about 90 degrees. In other embodiments, the predetermined angle is greater than or less than 90 degrees.

In one embodiment, a process may perform a sequence of actions in a different order. In another embodiment, a process may skip one or more actions. In other embodiments, one or more actions may be performed simultaneously. In one embodiment, additional actions may be taken.

While the above description contains particular embodiments of the invention, these should not be construed as limiting the scope of the invention but as illustrative of particular embodiments thereof. Therefore, the scope of the present invention should be determined not with the illustrated embodiments but with the appended claims and their equivalents.

Claims (28)

1. A system for changing an orientation of a plurality of row bars used in fabricating a magnetic head, the system comprising:

a base support, comprising:

a top surface; and

at least one support arm positioned on the top surface and configured to rotate relative to the top surface from a first position to a second position;

a tray assembly coupled to the at least one support arm, the tray assembly comprising:

a first tray comprising a plurality of first lanes, each first lane configured to hold one of the row bars in an initial position;

a transfer substrate comprising a plurality of transfer channels, each transfer channel configured to receive one of the row bars from the first tray as the support arm moves from the first position to the second position; and

a second tray comprising a plurality of second lanes, each of the second lanes configured to receive one of the row bars from the transfer substrate and to hold the one of the row bars in a final position, wherein the first tray and the second tray are configured to sandwich the transfer substrate therebetween,

wherein the row bar in the final position is rotated from the initial position by a preselected angle.

2. The system of claim 1, wherein the at least one support arm is configured to rotate about an axis parallel to the top surface from the first position along the top surface to the second position along the top surface, the second position being spaced apart from the first position.

3. The system of claim 1, wherein the at least one support arm comprises a first support arm and a second support arm, each support arm coupled to a shaft configured to rotate within at least one shaft holder attached to the top surface of the base support.

4. The system of claim 3, wherein the at least one shaft retainer comprises a first shaft retainer and a second shaft retainer, each shaft retainer attached to the top surface of the base support and comprising a circular opening configured to receive a portion of the shaft.

5. The system of claim 4, wherein the first shaft retainer and the second shaft retainer are spaced a preselected distance from each other.

6. The system of claim 5, wherein the preselected distance is approximately equal to a width of the first tray.

7. The system of claim 1, the preselected angle comprising about 90 degrees.

8. The system of claim 1, wherein the first and second sensors are disposed in a common housing,

wherein each of the row bars comprises an elongated rectangular shape having a rectangular cross-section taken along a width, the rectangular cross-section comprising a length,

wherein, in the initial position, a length of a cross-section of each of the row bars is positioned vertically relative to the top surface of the base support, an

Wherein, in the final position, a length of a cross-section of each of the row bars is positioned horizontally relative to the top surface of the base support.

9. The system of claim 1, wherein the first and second sensors are disposed in a common housing,

wherein each of the row bars comprises an elongated rectangular shape having a rectangular cross-section taken along a width, the rectangular cross-section comprising a length,

wherein, in the initial position, a length of a cross-section of each of the row bars is positioned horizontally relative to the top surface of the base support, an

Wherein, in the final position, a length of a cross-section of each of the row bars is positioned vertically relative to the top surface of the base support.

10. The system of claim 1, wherein each of the plurality of delivery channels comprises a cross-section taken along a width, the cross-section having a first end and a second end, wherein the width of the first end is less than the width of the second end.

11. The system of claim 10, wherein the first end abuts a first channel of the first tray and the second end abuts a second channel of the second tray.

12. The system of claim 1, wherein the first tray and the second tray comprise an approximately square shape.

13. The system of claim 1, wherein the first and second sensors are disposed in a common housing,

wherein each of the row bars comprises an elongated rectangular shape having a rectangular cross-section taken along a width, the rectangular cross-section comprising a length,

wherein each of the first channels of the first tray is shaped to receive a row bar such that a length of a cross-section of the row bar is positioned vertically relative to a top surface of the first tray, an

Wherein each of the second channels of the second tray is shaped to receive a row of bars such that a length of a cross-section of the row of bars is positioned horizontally relative to a top surface of the second tray.

14. The system of claim 1, wherein the transfer substrate is attached to the first tray and the second tray.

15. A method for changing the direction of a plurality of row bars used in the manufacture of a magnetic head, the method comprising:

positioning each of the plurality of row bars into one of a plurality of first lanes of a first tray, wherein each of the plurality of first lanes is configured to hold one of the row bars in an initial position;

positioning a transfer substrate comprising a plurality of transfer channels on the first tray such that the first channels and the transfer channels are aligned, wherein each transfer channel of the transfer substrate is configured to receive one of the row bars from the first tray;

positioning a second tray comprising a plurality of second channels on the transfer substrate such that the transfer channels and the second channels are aligned, wherein each of the second channels is configured to receive one of the row bars from the transfer substrate and hold the one of the row bars in a final position;

coupling the first tray, the transfer substrate, and the second tray to at least one support arm positioned on a top surface of a base support and configured to rotate relative to the top surface from a first position to a second position to form an assembly; and

moving the assembly from the first position to the second position, thereby moving the plurality of row bars from the initial position to the final position, wherein the row bars in the final position are rotated from the initial position by a preselected angle.

16. The method of claim 15, wherein the first and second light sources are selected from the group consisting of,

wherein moving the assembly from the first position to the second position comprises moving the assembly from a first position along the top surface to a second position along the top surface about an axis parallel to the top surface of the base support, the second position spaced from the first position, an

Wherein the at least one support arm is configured to rotate about an axis parallel to the top surface from the first position to the second position.

17. The method of claim 15, wherein the at least one support arm comprises a first support arm and a second support arm, each support arm coupled to a shaft configured to rotate within at least one shaft holder attached to a top surface of the base support.

18. The method of claim 17, wherein the at least one shaft retainer comprises a first shaft retainer and a second shaft retainer, each of the shaft retainers attached to the top surface of the base support and comprising a circular opening configured to receive a portion of the shaft.

19. The method of claim 18, wherein the first shaft retainer and the second shaft retainer are spaced a preselected distance from each other.

20. The method of claim 19, wherein the preselected distance is approximately equal to a width of the first tray.

21. The method of claim 15, the preselected angle comprising about 90 degrees.

22. The method of claim 15, wherein the first and second light sources are selected from the group consisting of,

wherein each of the row bars comprises an elongated rectangular shape having a rectangular cross-section taken along a width, the rectangular cross-section comprising a length,

wherein, in the initial position, a length of a cross-section of each of the row bars is positioned vertically relative to the top surface of the base support, an

Wherein, in the final position, a length of a cross-section of each of the row bars is positioned horizontally relative to the top surface of the base support.

23. The method of claim 15, wherein the first and second light sources are selected from the group consisting of,

wherein each of the row bars comprises an elongated rectangular shape having a rectangular cross-section taken along a width, the rectangular cross-section comprising a length,

wherein, in the initial position, a length of a cross-section of each of the row bars is positioned horizontally relative to the top surface of the base support, an

Wherein, in the final position, a length of a cross-section of each of the row bars is positioned vertically relative to the top surface of the base support.

24. The method of claim 15, wherein each of the plurality of transfer channels comprises a cross-section taken along a width, the cross-section having a first end and a second end, wherein the width of the first end is less than the width of the second end.

25. The method of claim 24, wherein the first end abuts a first channel of the first tray and the second end abuts a second channel of the second tray.

26. The method of claim 15, wherein the first tray and the second tray comprise an approximately square shape.

27. The method of claim 15, wherein the first and second light sources are selected from the group consisting of,

wherein each of the row bars comprises an elongated rectangular shape having a rectangular cross-section taken along a width, the rectangular cross-section comprising a length,

wherein each of the first channels of the first tray is shaped to receive a row bar such that a length of a cross-section of the row bar is positioned vertically relative to a top surface of the first tray, an

Wherein each of the second channels of the second tray is shaped to receive a row of bars such that a length of a cross-section of the row of bars is positioned horizontally relative to a top surface of the second tray.

28. The method of claim 15, wherein the transfer substrate is attached to the first tray and the second tray.