Method of manufacturing magnetic head slider

To provide a method of manufacturing magnetic head slider which is capable of improving the product quality, simplifying the manufacturing process, and reducing the manufacturing time. This method of manufacturing a magnetic head slider, formed by cutting out from a block member, includes the steps of: processing an end face of the block member forming one surface of a magnetic head slider; holding fixedly the end face of the block member processed; and while maintaining a holding state provided by the step of holding, cutting a portion of the end face side of the block member, and processing a cut surface of the cut portion forming another surface of the magnetic head slider.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of manufacturing magnetic head slider, and in particular, to a method of manufacturing magnetic head slider formed by cutting out from a block member and applied with surface processing.

2. Related Art

A magnetic head slider used for a hard disk drive is required to fly at a low amplitude above a magnetic disk with high accuracy. To achieve this, an ABS ((Air Bearing Surface) flying surface) in a predetermined shape must be formed on the surface facing the magnetic disk, and this surface must be processed by polishing (lapping) with high accuracy. At the same time, in polishing, the MR height (element length from the ABS) of the magnetic head element exposed on the ABS would be adjusted so as to perform data reading and writing to the magnetic disk. Since the MR height affects the accuracy of reading and writing performance to the magnetic disk, highly accurate adjustment is needed.

For these reasons, polishing of an ABS is an important step when processing a magnetic head slider. Further, the surface opposite to the ABS (back surface) is to be mounted on a suspension constituting a Head Gimbal Assembly (HGA), which affects the flying height above the magnetic disk. Therefore, highly accurate polishing is also required for the back surface.

Conventional method of manufacturing a magnetic head slider includes polishing of ABS and its back surface. First, a bar block, in which magnetic head sliders are aligned in a row, is cut out from a wafer where magnetic head elements of a plurality of magnetic head sliders are formed. Then, in a state where the back surface side with respect to the ABS is fixed to a predetermined jig, the ABS is polished. Next, the back surface is polished with the polished ABS side fixed to a predetermined jig. Then, pattern is formed through steps of etching the ABS, the bar block would then be cut into pieces of magnetic head sliders and the like, whereby a magnetic head slider is manufactured.

However, as hard disk drive has size reduction recently, the size of a magnetic head slider itself has been further miniaturized. Therefore, in the manufacturing process, handling such as fixing a member in a bar-block shape to a jig or the like is getting more difficult. In particular, direct handling of the minute and elongated fragile bar block would induce considerable damages to the magnetic head slider.

In view of the above, there are disclosed methods in which polishing of an ABS is performed before cutting into a bar block, and then cutting into a bar block shape, as shown in the following patent documents. Explanation will be given for these methods.

In a method disclosed in the publication of Japanese Patent Application Laid-open No. 11-316928 (Patent Document 1), first, a wafer block in which magnetic head sliders are aligned in a plurality of rows, that is, a wafer block consisting of plural rows of bar blocks, is cut out, and is mounted on a support plate. Next, ABS of magnetic head sliders positioned at the edge thereof is polished. Then, a tape is used so as to cover the polished ABS, and the bar block is cut out from the wafer block in such a state. Then, the bar block is held with vacuum tweezer and mounted on a jig for polishing the back surface, and the back surface is polished.

Similarly, in a method disclosed in the publication of Japanese Patent Document Laid-open No. 11-328642 (Patent Document 2), first, ABS is polished in a state of a wafer block, and then a bar block is cut out. Then, the bar block is adhered to a work holder with the ABS being the adhered surface, and the back surface is polished.

However, the conventional examples described above involve the following disadvantages. For instance, in either method, polishing of ABS is performed in a wafer block shape. In such method, although stable polishing of ABS can be realized, magnetic head sliders manufactured from an elongated fragile bar block may be damaged since the bar block is handled directly when the back surface is polished after cutting into a bar block.

More specifically, in Patent Document 1, polished ABS is covered with a taper but since it is mounted on a jig for processing the back surface by vacuum tweezer, it may be damaged or broken at that time. Further, a work to mount it on the jig is caused in the process. In Patent Document 2, on the other hand, polished ABS is adhered to a work holder so as to be protected, but it may be damaged when being adhered to the work holder, and also a work to mount it on the jig is caused in the process, similar to the above-described case. As mentioned above, in manufacturing electronic components required high product accuracy, problems of complication and delay of the manufacturing process are caused, in addition to the product quality's deteriorating. Moreover, an increase in the manufacturing cost is also a problem.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a method of manufacturing a magnetic head slider, capable of solving the disadvantages of the above-described conventional examples, and in particular, improving the product quality, simplifying the manufacturing process and reducing the manufacturing time.

In order to achieve the object, a method of manufacturing a magnetic head slider, which is a mode of the present invention, is a method of manufacturing a magnetic head slider formed by cutting out from a block member, including the steps of: processing an end face of the block member forming one surface of the magnetic head slider (end face processing step); holding fixedly the end face of the block member processed (holding step); and while maintaining the holding state provided by the holding step, cutting a portion of the end face side of the block member (cutting step), and processing a cut surface of the cut portion forming another surface of the magnetic head slider (cut surface processing step).

According to the invention described above, an end face of the block member forming one surface of a magnetic head slider is processed first, and the processed end face is held. Then, while maintaining the holding state, a portion of the end face side including a magnetic head slider is cut out, and another surface of the magnetic head slider which is the cut surface of the cut out portion is processed. In this way, since cutting and processing of the cut surface are performed in the state of fixing the cut out portion, the process can be stabilized, and it is possible to prevent handling of a small-sized cut-out portion such as mounting on a processing device. Thereby, damage and breakage which may be caused on the magnetic head slider can be minimized. Accordingly, it is possible to simplify and speed-up the manufacturing process, to prevent damage on the magnetic head slider, and to manufacture a magnetic head slider of higher quality at lower cost.

Further, in the holding step, it is desirable to hold and cover the end face of the block member processed in the step of processing the end face. In the meantime, it is more desirable to hold via a protective member covering the end face of the block member. Thereby, since the end face, processed before being held, is held in the state of being protected, it is possible to effectively prevent damage on the magnetic head slider at the time of cutting and processing of the cut surface, which leads to an improvement in the product quality.

Further, in the holding step, the end face of the block member is held by a holding jig via an adhesive member adhering to the holding jig. In particular, in the holding step, the end face of the block member is held by being adhered to the holding jig with a double-faced tape. Thereby, the end face, processed before being held, is held in the state of being adhered to the holding jig with an adhesive member, so it is possible to stabilize cutting and processing of the cut surface, and to prevent damage on electronic components more effectively at the time of processing. Particularly, it is possible to simplify and speed-up the holding step by adhering them with a double-faced tape.

Note that the adhesive member is desirably a member having elasticity and conductivity. With such properties, it is possible to protect the end face against impact with the adhesive member and to prevent damage when holding the processed end face. Further, since the adhesive member has conductivity, it is possible to prevent electrostatic discharge damage of the magnetic head slider to be manufactured.

Further, the method further includes a step of releasing the holding state provided by the holding step (hold releasing step), after the cut surface processing state. The hold releasing step is, in particular, a step of separating adhered state of the end face of the block member and the holding jig with the adhesive member. For example, the adhesive member may be a member to be separated at a prescribed temperature, and in the hold releasing step, the holding state is released by heating the adhesive member up to the prescribed temperature. Alternatively, the adhesive member may be a member to be separated by being added with a prescribed solvent, and in the hold releasing step, the holding state is released by adding the prescribed solvent to the adhesive member. At this time, in the hold releasing step, a part held by the holding jig is dipped in the prescribed solvent. Further, it is more desirable to ultrasonic-vibrate the prescribed solvent in which the part held by the holding jig is dipped.

Since the holding state with the adhesive member and the like is released after cutting from the block member and processing of the cut surface have been performed, it is possible to obtain a portion which can be formed as a magnetic head slider to which high-quality processing has been performed as described above. Particularly, since the adhesive member is separated by heating or with solvent, it can be taken out quickly and easily and mechanical stress applied onto the magnetic head slider is minimized. These lead to a further improvement in the quality of the magnetic head slider.

Further, in the end face processing step, a surface facing a magnetic disk of the magnetic head slider is polished, and in the cutting step, a bar block in which a plurality of magnetic head sliders are arranged in a row is cut out from the block member, and in the cut surface processing step, a back surface with respect to the surface facing the magnetic disk of the magnetic head slider is polished. As described above, although process performed to the magnetic head slider includes polishing, such polishing is performed to the block member in the holding state provided by the holding step, so polishing can be performed stably. Accordingly, it is possible to effectively perform manufacturing of a magnetic head slider requiring high accuracy.

(Effects of the Invention)

The present invention is formed and worked as described above, whereby it is possible to stably process one end face of the magnetic head slider in the block member state, and then cutting and processing of the cut surface can be performed stably in the state of holding the one end face side. Accordingly, the present invention has such excellent effects as to stabilize, simplify and speed-up the manufacturing process, and to prevent damage on the magnetic head slider, whereby a high-quality magnetic head slider can be manufactured at low cost, which could not be achieved conventionally.

DESCRIPTION OF PREFERRED EMBODIMENTS

A method of manufacturing a magnetic head slider, which is the present invention, is characterized in that an end face of a block member, forming one surface of magnetic head slider, is processed, and in a state where the processed end face is held, the end face side is cut out, and another surface of the magnetic head slider, which is the cut surface of the cut-out portion, are processed. Hereinafter, specific examples thereof will be explained with reference to respective embodiments.

Note that the manufacturing methods described below are also applicable to manufacturing electronic devices other than magnetic head sliders. That is, they are also methods of manufacturing electronic components manufactured by cutting out from a block member and processing the cut surface.

A first embodiment of the present invention will be explained with reference toFIGS. 1A to 9.FIGS. 1A and 1Bare illustrations showing processing objects processed to be magnetic head sliders.FIGS. 2 to 7are diagrams showing an apparatus and a method for manufacturing a magnetic head slider.FIG. 8is a flowchart showing a method of manufacturing a magnetic head slider.FIG. 9is a diagram showing a variation or an apparatus and a method for manufacturing a magnetic head slider.

An apparatus for manufacturing a magnetic head slider in the present invention is an apparatus for manufacturing pieces of magnetic head sliders in such a way that a wafer block10shown inFIG. 1Bconsisting of laminated bar blocks11, in which a plurality of magnetic head sliders12are aligned in a row, is cut out from a wafer W shown inFIG. 1A, and the wafer block10is processed. The apparatus for manufacturing a magnetic head slider has, in particular, such a configuration that the bar blocks11are cut out and the cut surface11bis processed, which is a characteristic of the present invention.

More specifically, the apparatus for manufacturing a magnetic head slider of the present embodiment includes: a wafer block holder1for holding the wafer block10; an end face processor2(end face processing device) for processing the end face11aof the wafer block10; an end face holder3(holding device) for fixedly holding the processed end face of the wafer block10; a cutter4(cutting device) for cutting a bar block from the wafer block10; a cut surface processor5(cut surface processing device) for processing the cut surface; and a solvent bath6(hold releasing device) for releasing the holding state of the wafer block10held by the end face holder3, as shown inFIGS. 2 to 7. Hereinafter, each configuration will be described in details.

The magnetic head slider12is formed such that magnetic head element parts are formed by laminating a thin film on the wafer W and are cut into pieces. In order to do so, first, a wafer block10consisting of laminated bar blocks11, in which a plurality of magnetic head sliders12are aligned laterally in a row, is cut out as described above. Then, the wafer block10is cut into bar blocks11, and finally, cut into pieces of magnetic head sliders12.FIG. 1Ashows a state of the wafer W before the wafer block10is cut out, andFIG. 1Bshows a state of the cut-out wafer block10.

One end face11aof the wafer block10serves as an ABS of a magnetic head slider12formed from the bar block11positioned at the edge part, that is, a flying surface facing a magnetic disk. Accordingly, on the ABS11a,an MR element13for performing reading and writing of data to a magnetic disk is exposed in a magnetic head element part formed at an edge of the magnetic head slider12. In order to adjust the MR height (element length from the ABS) of the MR element13, polishing of the end face is performed as described below. Further, the bar blocks11are cut out one by one from the end part of the wafer block10, as described later.

As shown inFIG. 2, in the wafer block10, an end part (the other end part) opposite to the end part where the ABS11ais formed is held by the wafer block holder1. The wafer block holder1fixedly holds the other end part of the wafer block10with an adhesive (not shown) on the holding face. An adhesive used has a characteristic of adhering when heated, and further, has a characteristic that when a prescribed solvent is added, the adhesive strength is weaken so that it can be separated, same as a double-faced tape32described later. However, any method of holding the other end part of the wafer block10by the wafer block holder1is acceptable, so the wafer block holder1adopts a configuration corresponding to the holding method.

Note that the other end face of the wafer block10held by the wafer block holder1is polished by using a polishing device not shown before being held. That is, the other end face becomes the back surface, with respect to the ABS, of the magnetic head slider12cut out from the bar block11positioned at the lowermost layer, so it is polished while fixing the wafer block10to a predetermined jig, for example. Since the wafer block10is in a large shape when the back surface is processed, even though the wafer block10is fixed with a cramp-type jig, it is possible to prevent damage which may be caused thereto. However, any holding method is acceptable, so the wafer block10may be held such that a part other than that to be processed is adhered with a double-faced tape.

The end face processor2is disposed on the opposite side to the part held by the wafer block holder1. That is, as shown inFIG. 2, it is disposed on one end face side of the wafer block10so as to perform processing of the surface serving as the ABS11aof the magnetic head slider12. Particularly, the end face processor2of the present embodiment is a polishing device for polishing the ABS11a.

The end face processor2is drive-controlled by a driving device or a controlling device not shown, and moves so as to contact the one end face11aof the wafer block10as shown by the arrow inFIG. 2, and polish the ABS11awhich is the one end face. Here, polishing is performed to adjust the MR height of the MR element13exposed on the ABS11a, and at the same time, polishing is performed to form a predetermined surface roughness so as to realize highly accurate flying above a magnetic disk.

Next, the end face holder3will be explained with reference toFIG. 3. The end face holder3is a device for fixedly holding the ABS11awhich is the one end face of the wafer block10processed as described above. The end face holder3is disposed above the ABS11a,instead of the end face processor2, after the ABS11ahas been processed.

The end face holder3has an end face holding jig31for holding one end face of the wafer block10, and a double-faced tape32adhered on the holding face of the end face holding jig31. Although not shown, the end face holder3also includes a driving device and a controlling device for drive-controlling the end face holding jig31. The end face holder3is driven such that the holding face on which the double-faced tape32is adhered contacts the one end face11a, which has been polished, of the wafer block10, as shown by the arrow inFIG. 3. Thereby, the holding face of the end face holding jig31and the one end face11a(ABS) of the wafer block10are in a state of being adhered with the double-faced tape32, whereby the bar block11of the one end face11aside of the wafer block is in a state of being held fixedly by the end face holding jig31.

The end face holder3maintains a state of holding the one end face11aof the wafer block10by adhering to it with the double-faced tape32at the time of cutting the wafer block10and processing the cut surface which will be described later. Accordingly, after the cutting, the end face holder3is move-driven to a position where the cut surface can be processed while holding the bar block11cut out from the wafer block10.

The double-faced tape32has an area covering at least the one end face11aof the wafer block10, that is, all over the ABS11aprocessed by the end face processor2described above, and is attached so as to cover the ABS11a.Thereby, the double-faced tape32covers all over the polished ABS11a, so it serves as a protective member for preventing damage on the ABS11a.

Further, the double-faced tape32is made of an elastic member having a predetermined elasticity. Thereby, the processed ABS11acan be further protected appropriately. However, it is desirable that the elasticity and elastic range of the double-faced tape32be in a level not affecting processing of the surface opposite to the ABS11a(back surface11b) described later. Further, the double-faced tape32is a conductive member, and corresponding to it, the end face holding jig31is also a conductive member. Therefore, it is possible to suppress generation of electrostatic discharge damage of the wafer block10held, that is, of the magnetic head slider12.

Further, the double-Laced tape32is a member which is separated when a prescribed solvent is added since the adhesive strength is weakened. This is for easily separating the bar block11from the end face holding jig31by using solvent after cutting the wafer block10and polishing the cut surface described later.

However, it is not necessary to use the double-faced tape32for holding the one end face11aof the wafer block10. Instead of the double-faced tape32, the wafer block10may be adhered to the end face holding jig31by using another adhesive member such as an adhesive having the above-described characteristics. It is desirable that a substituting adhesive member have the characteristics held by the double-faced tape32, but it is not limited to have the above-described characteristics.

Next, the cutter4will be explained with reference toFIG. 4. The cutter4includes a blade41for cutting and a driving device42for rotationally driving the blade, and operates so as to cut a bar block11positioned at one end face side of the wafer block10. That is, the cutter4cuts the boundary between the bar block11held by the end face holder3and a bar block positioned at the lower layer thereof (see the arrow inFIG. 4). Since the one end face side of the wafer block10is held fixedly when cut by the cutter4, cutting is performed stably.

FIG. 5shows a state where the bar block11is cut out from the wafer block10by the cutter4. As shown inFIG. 5, the cut bar block11is held by the end face holder3, and is an object of processing by the cut surface processor5which will be explained below. The remaining wafer block10is held by the wafer block holder1, and is again to be an object of processing by the end face processor2and the like described above.

Next, the cut surface processor5will be explained with reference toFIG. 6. The cut surface processor5is a device for processing the cut surface of the bar block11cut out from the wafer block10, that is, a surface opposite to the ABS11a(back surface11b) of the bar block11. Therefore, the cut surface processor5is disposed so as to be positioned on the back surface side of the bar block11, that is, below the bar block11in the example shown inFIG. 6, after cutting. The cut surface processor5moves such that the processing face contacts the back surface11bof the bar block11(see the arrow inFIG. 6), and performs processing. The cut surface processor5of the present embodiment is a polishing device for polishing the back surface11. In polishing, the bar block11is in a state of being held by the end face holding jig31, so polishing is performed stably.

Next, the solvent bath6(solvent adding device) will be explained with reference toFIG. 7. The solvent bath6is a container filled with prescribed solvent61for weakening the adhesive strength of the double-faced tape32described above. Near the opening thereof, there is a holder member62to which the end face holder3holding the bar block11is set. The holder member62has an opening on the upper face side, and a receiver62ais formed in a dented shape with an inner bottom face. The receiver62ain a dented shape is to be filled with the solvent61as described later.

As shown inFIG. 7, near the opening of the holder member62, the end face holder3can be set as a whole while holding the bar block11in which the cut face has been polished, on the lower side thereof. Therefore, when the end face holder3is set, the bar block11and the double-faced tape32are dipped in the solvent61filled in the dented receiver62a.Note that the inner bottom face of the receiver62aserves to receive the bar block11separated from the end face holder3as described later.

In the bottom face of the holder member62, that is, in the receiver62a, a plurality of through holes62bpenetrating to the outside (in a lower direction) are present. This enables the solvent61in the solvent bath to flow into the receiver62aof the holder member62. Then, the dented receiver62ais filled with the solvent61up to a level near to the opening of the holder member62. Note that the opening of the holder member62is formed to have an area sufficient for dipping a part where the bar block11is adhered to the end face holder3, that is, a part of the double-faced tape32.

Further, the bottom face of the solvent bath6is provided with an ultrasonic vibrator63for applying ultrasonic vibration to the solvent61. Accordingly, ultrasonic vibration generated from the ultrasonic vibrator63passes through the through holes62bformed in the holder member62mediated by the solvent61, and is transmitted to the solvent61filled in the dented receiver62a.

Thereby, the solvent61is added to the double-faced tape32with which the bar block11is adhered to the end face holding jig31. Further, since ultrasonic vibration is applied, the adhesive strength of the double-faced tape32is weakened efficiently in a short period. Consequently, the bar block11is separated from the end face holding jig31. In other words, the solvent bath6and the solvent61serve as separating devices.

In this way, the bar block11, in which the ABS11aand the back surface11bare polished, is separated from the end face holder3and is accommodated in the receiver62aof the holder member62. Accordingly, by collecting the holder member62as a whole, the bar block11can be collected easily.

Note that the solvent bath6shown inFIG. 7is also used for separating the wafer block10held by being adhered with an adhesive, that is, the last bar block11, from the wafer block holder1described above. At this time, it is only necessary to dispose the wafer block holder1on the holder member62with the last bar block11facing downward and to dip the holder member62in the solvent61, same as the end face holder3shown inFIG. 7.

The apparatus for manufacturing a magnetic head slider also includes configurations for forming pieces of magnetic head sliders12from the bar block11. For example, the apparatus includes a device for forming patterns on the ABS11aby dry etching, and a device for cutting the bar block11into pieces of magnetic head sliders12. These configurations are devices typically used, so the detailed explanations thereof are omitted.

Next, a method of manufacturing a magnetic head slider using the manufacturing apparatus described above will be explained with reference to the flowchart inFIG. 8andFIGS. 1A to 7described above.

First, as shown inFIG. 1, the wafer block10in which the bar blocks11are laminated in a plurality of rows is cut out from the wafer W (step S1). Then, the other end part of the wafer block10, that is, an end surface opposite to the end side where the ABS11ais formed (back surface11b) is polished (step S2). Then, as shown inFIG. 2, the polished end surface (back surface11b) is held fixedly by the wafer block holder1by using an adhesive which will be separated by using the solvent61(step S3).

Next, in a state where the other end side of the wafer block10is held, the end face processor2is disposed on the surface of one end side, that is, the ABS11aside, of the wafer block10to thereby polish the ABS11a(step S4, end face processing step). Here, polishing is performed so as to make the MR height of the MR element13exposed on the ABS11ato be an appropriate length and to realize an appropriate surface roughness. As described above, steps S3and S4are performed in a state where the wafer block10is held by the wafer block holder1(step SA).

When the polishing of the ABS lie has been completed, it is checked whether two or more bar blocks are laminated in the wafer block10, that is, whether there is a part to cut out the bar block11(step S5). If there is a cut part (positive determination in step S5), the end face holder3is disposed on the ABS11aside, and the double-faced tape32adhered to the holding face of the end face holding jig31is adhered to the ABS11a(step S6, holding step). At this time, it is preferable to align such that the double-faced tape32covers all over the polished ABS11a.Thereby, one end face of the wafer block10and the holding face of the end face holding jig31are in a state of being adhered with the double-faced tape32, so the one end face side of the wafer block10is held by the end face holder3.

Then, cutting of the bar block11is performed. That is, as shown inFIG. 4, the cutter4is disposed at a position between the bar block11held by the end face holder3and a bar block positioned in the lower layer thereof. The bar block11held is cut out while maintaining the holding state of the one end face (ABS side) of the wafer block10by the end face holder3(step S7, cutting step). Note that steps S6and S7are carried out in a state where the wafer block10is held by both of the wafer block holder1and the end face holder3(step S8).

Then, to the bar block11side cut out from the wafer block10(proceed to (2) in step S8), polishing of the cut surface11bof the bar block11is performed while holding the bar block11by the end face holder3. That is, the cut surface processor5is disposed facing the back surface11bopposite to the ABS ha of the cut-out bar block11, and polishing is performed to the back surface11b(step S9, cut surface processing step). Thereby, the back surface11bwhich is the surface mounted on the Head Gimbal Assembly can be polished with high accuracy to have a predetermined surface roughness.

Next, the holding part of the end face holder3, to which the bar block11is adhered with the double-faced tape32, is disposed on the holder member62of the solvent bath6and is dipped in the solvent61, while being applied with ultrasonic vibration by the ultrasonic vibrator63. As a result, the adhesive strength of the double-faced tape32is weakened by the solvent61, whereby the bar block11is separated from the end face holder3(step S10, hold releasing step). Note that steps S9and S10described above are performed in a state where the bar block11is held by the end face holder3(step SC). By collecting the holder member62from the solvent bath6, the separated bar block11is collected from the receiver62aof the holder member62. Thereby, the bar block11, in which both of the ABS11aand the back surface11bare polished, is obtained.

In step S5described above, if only one bar block11remains in the wafer block10after polishing the ABS in the wafer block10(negative determination in step S5), cutting is not needed any more, so an operation of removing the last bar block11from the wafer block holder1is performed. At this time, by setting the holding part of the wafer block holder1to the holder member62and dipping it in the solvent61same as step S10described above, the solvent61is added to the adhesive (or a double-faced tape, etc.) used for holding in the same manner as described above, whereby the last bar block11is separated. Since the back surface11bof the bar block11has been polished first (step S2), the bar block11in which the both surfaces are polished is obtained.

Further, in step S8, to the wafer block10after the bar block11is cut out (proceed to (1) in step S8), polishing is again performed to the ABS11aserving as the end face in the state of being held by the wafer block holder1, and cutting, cut surface polishing and steps S4to S7described above are repeated.

Then, to the bar block11in which the both surfaces are polished, processing for forming magnetic head sliders12, such as forming ABS using dry etching and cutting into pieces of sliders, is performed (step S11).

Through these steps, the bar block11is cut out and the cut surface is polished in a state where one end face of the wafer block is held Therefore, it is possible to prevent handling of fragile bar block11, which has been cut out, for mounting on a jig for performing back surface polishing, for example, Accordingly, it is possible to prevent damage and breakage on the magnetic head sliders12in the bar block11to thereby manufacture high quality products. Further, it is possible to stabilize, simplify and speed-up the manufacturing process, which also leads to low manufacturing cost.

Further, since the polished ABS11ais adhered to the end face holder3with the double-faced tape32, the polished ABS11acan also be protected appropriately at the time of another processing. At the same time, since it is held with the double-sided tape32adhered thereto, it is possible to simplify and speed-up the holding step, and cutting step and polishing step related thereto.

Further, since the adhesive strength of the double-faced tape32is weakened so as to separate the bar block11from the end face holder3, it is possible to minimize unnecessary stress applied to the bar block11, to prevent damage on the magnetic head slider12, and to improve quality of the product. Further, by ultrasonic-vibrating the solvent61, it is possible to improve the separation efficiency, so the separating process can be performed faster and a separated state suppressing an influence on the product can be obtained.

As described above, the manufacturing method and the manufacturing apparatus described above are preferable in manufacturing high-quality electronic components. Therefore, by applying those methods in manufacturing magnetic head sliders requiring high accuracy, it is possible to obtain more advantages described above.

Another exemplary configuration of the solvent bath6, which is a solvent adding device for performing solvent separation from the end face holder3in step S10ofFIG. 8as described above, will be explained with reference toFIG. 9.

The solvent bath6shown inFIG. 9is a container filled with the prescribed solvent61which weakens the adhesive strength of the double-faced tape32described above, having an opening with sufficient area for dipping the part where the bar block11is adhered to the end face holder3, that is, the part of the double-faced tape32. From this opening, the bar block11, in which the cut surface has been polished, is dipped with the whole end face holder3as described above. Thereby, the solvent61is added to the double-faced tape32, so that the adhesive strength of the double-faced tape32is weakened, whereby the bar block11is separated from the end face holding jig31. Consequently, the bar block11, in which the ABS11aand the back surface11have been polished, is dropped in the solvent bath6. Accordingly, by disposing a tray for collecting the bar block11in the solvent bath6and collecting the tray, the bar block11is collected easily.

As described above, it is not necessary to provide the above-described holder member62and ultrasonic vibrator63shown inFIG. 7in the solvent bath6. Further, the configurations of the solvent adding device for separating the bar block11from the end face holding jig31are not limited to the above-described configuration. For example, the solvent61may be added to the double-faced tape32by spraying the solvent61to the adhered part between the bar block11and the end face holding jig31, or yet another configuration may be adopted.

Next, a second embodiment of the present invention will be explained with reference toFIGS. 10 to 11.FIG. 10is a diagram showing a part of an apparatus for manufacturing a magnetic head slider of the present embodiment.FIG. 11is a flowchart showing a manufacturing method.

A method of manufacturing a magnetic head slider in the present embodiment is almost same as the method described in the embodiment 1, but is different in that a step of separating the bar block, in which the back surface has been processed, from the end face holder3is not a method using the solvent61. Accordingly, the apparatus is also different. Hereinafter, the configuration will be explained with reference toFIG. 10, and the operation will be explained with reference toFIG. 11.

The end face holder3of the present embodiment includes a double-faced tape33for adhering and holding one end face of the wafer block10, that is, the bar block11to be cut out, same as that described above. The double-faced tape33is a member particularly having such a characteristic that the adhesive strength is weakened when heated to a prescribed temperature so it is separated. The prescribed temperature is, for example, a level not lower than a room temperature (e.g., 25° C.) but not thermally destructing the magnetic head slider12(e.g., 90° C. Even in the case of using another adhesive material such as an adhesive instead of the double-faced tape33, a material having such a characteristic can be used.

Further, the hold releasing device for releasing the holding state of the bar block11, which is a part of the manufacturing apparatus of the present embodiment, is a heater7as shown inFIG. 10. The heater7is, for example, a device for applying heat by contacting the end face holding jig31from the side opposite to the holding face of the bar block11as shown by the arrow inFIG. 10. Thereby, the applied heat is transmitted to the double-faced tape33adhered to the holding face as shown by the arrows of dotted lines inFIG. 10. When the temperature of the double-faced tape33reaches a predetermined temperature, the adhesive strength is weakened and the bar block11is separated from the end face holding jig31.

However, the configuration of the heater7is not limited to the configuration described above, and may be one heating the double-faced tape33by any means. For example, a configuration of blowing hot air to the holding face or a configuration of heating in a heating room is also acceptable.

Next, a method of manufacturing a magnetic head slider of the present embodiment will be explained with reference to the flowchart ofFIG. 11andFIG. 10described above. Since most steps are same as those of the embodiment 1, explanation will be given briefly.

First, the wafer block10, in which the bar blocks11are laminated in a plurality of rows, is cut out from the wafer W (step S21). Then, the other end of the wafer block10, that is, the back surface11bwhich is the end face opposite to the end side where the ABS11ais formed, is polished (step S22), and the polished back surface11bside is held fixedly by the wafer block holder1by using an adhesive (step S23). Note that an adhesive used here has a characteristic of being separated when heated, same as the double-faced tape33described above.

Next, in a state where the other end side of the wafer block10is held, the surface of the one end side of the wafer block10, that is, the ABS11a,is polished (step S24, end face processing step). Then, if there is a part to cut out the bar block11(positive determination in step S25), the double-faced tape33adhered to the holding face of the end face holding jig31is adhered to the ABS11a.Thereby, the one end face of the wafer block10and the holding face of the end face holding jig31are in a state of being adhered with the double-faced tape32, whereby the one end face side of the wafer block10is held by the end face holder3(step S26, holding step). Note that the double-faced tape33has a characteristic of being separated when heated as described above.

Next, the bar block11is cut out while holding the one end face of the wafer block10(step S27, cutting step). Then, on the end face holder3side, the cut surface11bof the bar block11is polished while maintaining the state of holding the cut-out bar block11(proceed to (2) in step S28, step S29, cut surface processing step). On the other hand, on the wafer block holder1side, steps S24to S27are repeatedly performed to the remaining wafer block10.

Next, by contacting the heater7to the end face holding jig31in the state where the bar block11is adhered with the double-faced tape33, the double-faced tape33is heated via the end face holding jig31. Then, when the double-faced tape33is heated up to the prescribed temperature, the adhesive strength of the double-faced tape33is weakened, whereby the bar block11is separated from the end face holding jig31(step S30, hold releasing step). Then, by collecting the separated bar block11, the bar block11in which both of the ABS11aand the back surface11bare polished is obtained.

In step S25, if there is no cutting part, that is, if the wafer block10held by the wafer block holder1consists of one bar block11(negative determination in step S25), heating is performed so as to separate the bar block11from the wafer block holder1(step S30). Since the separated back surface11bhas been polished (see step S22), the bar block in which the both surfaces are polished is obtained.

After these steps, processing for forming magnetic head sliders12such as forming patterns on the ABS and cutting into pieces of sliders is performed to the bar block11with both surfaces polished (step S31).

Through these steps, there is no need to remove the bar block11from the end face holding jig31by applying unnecessary stress to the bar block11, it is therefore possible to minimize applying of unnecessary mechanical stress, and to prevent damage on the magnetic head slider. Therefore, it is possible to manufacture a high-quality magnetic head slider.

INDUSTRIAL APPLICABILITY

The present invention can be used for manufacturing a magnetic head slider to be mounted on a hard disk drive, and has industrial applicability.