A discrete track thin film magnetic record disk and a method of making it

Abstract: A discrete track thin film magnetic metal or oxide record disk is made by forming a thin film (12) of magnetic material on a substrate (10), patterning the magnetic film with a chemically etchable support layer (14) and a high resolution photoresist layer (16), removing portions of the magnetic film and refilling with nonmagnetic material to form concentric nonmagnetic guard bands (32), and then applying a top layer (33) of additional nonmagnetic material as a passivating and protective disk overcoat after removal of the remaining support layer and photoresist. The exposed photoresist and portions of the chemically etchable support layer beneath the side walls of the patterned photo­ resist defining the edges of the magnetic tracks are removed in a photoresist developer which also creates undercuts in the support layer beneath the side walls. The undercuts prevent "fences" and provide smooth interfaces between the magnetic tracks and the nonmagnetic guard bands. In one embodiment of the disk, a continuous layer of nonmagnetic material serves as both the guard bands and the protective overcoat and has a height in the guard band regions greater than the height of the adjacent magnetic tracks so as to prevent damage to the magnetic tracks in the event the magnetic tracks are contacted by a slider supporting a read/write head.

Description: This invention relates to a discrete track thin film magnetic record disk and to a method of making it. Conventional thin film magnetic recording disks typically comprise a substrate, such as an aluminum alloy disk with a nickel-phosphorus (NiP) surface film, a film of magnetic metal alloy or metal oxide formed on the substrate, and a protective overcoat formed over the magnetic film. Such disks may be fabricated by evaporating or plating the magnetic film on the substrate, or in the more conventional approach by sputter depositing the magnetic film. Regardless of the specific composition of the magnetic film or the method of fabrication of the disk, all such commercially available disks utilize a continuous film of the magnetic metal alloy or metal oxide. Thus, during operation of the disk file, data may be recorded at any radial position of the disk where the continuous magnetic film is deposited. Because the read/write head cannot always be precisely aligned over any predetermined radial position on the disk, new data recorded over a previously recorded track may be recorded on the disk in a radial position slightly offset from the track where the previous data was recorded. This may occur even though the previous data and the new data are identified as having been recorded on the same data track. When the read/write head reads the signal from this track it will also pick up previously recorded signals on the disk at the edges of the track. An additional problem with the use of continuous magnetic film in thin film disks is that because magnetic media extends radially on the disk on both sides of the read/write head, fringe magnetic fields from the read/write head during recording will generate magnetic patterns at the edges of the track. This creates disorientation of the magnetic domains in the film at the track edges which results in noise when the recorded signal is read back. Conventional thin film disks which have a continuous magnetic film also require a nonmagnetic overcoat of sufficient thickness to not only passivate the magnetic film from the atmosphere but also to provide a durable protective barrier when the disk surface is contacted by the air bearing slider which supports the read/write head. In order to overcome the above shortcomings, thin film disks with discrete magnetic tracks separated by discrete nonmagnetic guard bands or separator tracks have been proposed. A variation of such a discrete track disk is described in GB- 1,443,248. In the process described in that document, discrete tracks of low coercivity magnetic oxide are formed from a continuous film of magnetic oxide by ion implanting cobalt ions through a mask to generate concentric spaced-apart high coercivity separator tracks. The cobalt-doped high coercivity separator tracks may also serve to record head positioning servo information. The IBM Technical Disclosure Bulletin (TDB), October 1975, at page 1641, describes a discrete track thin film disk formed by depositing a film of iron or cobalt over a resist pattern previously formed on a thin film of alpha iron oxide. The disk structure is then annealed to diffuse the iron or cobalt into the alpha iron oxide to transform it into ferromagnetic material. When the resist is removed, the result is a disk with discrete magnetic tracks separated by discrete tracks of nonmagnetic alpha iron oxide. The IBM TDB, January 1980, at page 3268, describes a discrete track disk in which the discrete magnetic tracks are formed by depositing a magnetic film (or magnetic particles) into concentric grooves which have been preformed on a substrate. Japanese Kokai 58-212624 describes a discrete track thin film disk in which concentric separator tracks are formed on a continuous magnetic iron oxide film by laser radiating the disk in a concentric track pattern so as to render the concentric tracks of the iron oxide film non magnetic. Japanese Kokai 59-112434 describes a particulate disk (i.e. a disk with a conventional magnetic coating of iron oxide particles dispersed in an organic binder) in which gaps are generated in the organic coating by forming a patterned photoresist film over the organic coating and then acid etching the organic coating. The invention seeks to provide an improved method of making a discrete track thin film magnetic record disk. The invention provides a method of making a discrete track magnetic record disk comprising the steps of: forming a continuous film of magnetic metal or oxide on a disk substrate; forming a support layer of chemically etchable material on the magnetic film; forming a layer of photoresist on the support layer; exposing selected regions of the photoresist layer to radiation; developing the photoresist layer to define a predetermined pattern of unexposed photoresist over the magnetic film, said pattern including concentric rings having side walls oriented generally perpendicularly to the disk substrate; removing the support layer material from areas between the concentric rings of the unexposed photoresist and from beneath the side walls of the concentric rings of the unexposed photoresist; removing the magnetic film in areas not patterned by the unexposed photoresist so as to leave magnetic metal or oxide on the substrate, the remaining magnetic metal or oxide defining a pattern of concentric tracks corresponding to the pattern of concentric rings of unexposed photoresist; refilling the voids created by the removal of the magnetic metal or oxide with nonmagnetic material to at least the height of the magnetic tracks; and removing the remaining photoresist and the remaining support layer material. The invention also provides a discrete track thin film magnetic record disk for use in a disk file of the type wherein an air-bearing slider supports a read/write head, the disk comprising: a plurality of discrete concentric tracks of magnetic metal or oxide formed on a substrate, the top surfaces of the discrete tracks being substantially coplanar; and a continuous layer of nonmagnetic material formed over the top surfaces of the tracks and over the substrate between the tracks, the height of the continuous layer in the regions between the tracks being at least as high as that in the regions on top of the tracks. Preferably, the nonmagnetic material deposited to fill the voids created by the removal of the magnetic film is deposited to a height slightly higher than the magnetic film so that the subsequently deposited nonmagnetic material creates a disk structure in which the guard bands are raised slightly above the magnetic tracks. This results in the guard bands functioning both to separate the discrete magnetic tracks and to protect the magnetic tracks from contact by the slider which supports the read/write head. Because the slider cannot contact the magnetic tracks in such a disk structure, the protective overcoat on top of the magnetic tracks needs only to have a thickness sufficient to provide passivation from exposure to the atmosphere. How the invention can be carried out will now be described by way of example, with reference to the accompanying drawings, in which: Figs. 1A-1H illustrate a portion of a record disk in a sectional view taken along a radius of the disk during consecutive steps of the fabrication process; Fig. 1H is a sectional view taken along a disk radius of a portion of the disk illustrating the resulting disk structure wherein the protective overcoat over the nonmagnetic guard bands is elevated relative to the overcoat over the magnetic tracks; Fig. 2A is a sectional view taken along a disk radius of a portion of a record disk following one step in an alternative process for making embodiment of the disk; and Fig. 2B is a sectional view taken along a disk radius of a portion of the disk made according to a fabrication process which includes the step illustrated in Fig. 2A, wherein the protective overcoat has a planar surface. In the fabrication of a discrete track thin film record disk by a process embodying the invention, a continuous film 12 of a magnetic cobalt-based alloy is sputter deposited to a thickness of approximately 30nm on a substrate 10 consisting of a nickel-phosphorus surface film plated on an aluminum alloy disk (not shown). The magnetic film 12 may alternatively be a magnetic metal oxide, such as sputtered gamma iron oxide, and may be formed by processes other than sputter deposition, such as plating or evaporation. Substrate 10 may alternatively be made of any suitable material, such as glass, ceramic or single crystal, semiconductor grade silicon. Also, as is conventional in thin film disk fabrication processes, a nucleating film (not shown in Fig. 1A), such as a chromium or chromium alloy film, can be sputter deposited on the substrate 10 before the magnetic film 12 is sputter deposited onto the nucleating film. After the magnetic film 12 has been formed on the substrate 10, a support layer 14 of a chemically etchable material is formed, as shown in Fig. 1B, on the magnetic film 12. In the preferred embodiment, the layer 14 is low molecular weight (e.g. 32,000) poly(dimethyl glutarimide), a photoresist material, and is spun onto the surface of magnetic film 12. The layer 14 is formed to a thickness of approximately 100nm, after which the disk is baked at approximately 180 degrees C for approximately 30 minutes. Layer 14 may alternatively be formed of poly(methyl methacrylate) (PMMA), which is soluble in an organic solvent. As shown in Fig. 1C, a second layer 16 of high resolution photoresist is spun to a thickness of approximately 1 micron over the support layer 14. The photoresist 16 may be any commercially available high resolution photoresist, such as Kodak 820 or Shipley 1470. The photoresist layer 16 is baked at approximately 95 degrees C for approximately 30 minutes. A photolithographic mask is then prepared which has a radiation-opaque pattern corresponding to the desired pattern of magnetic material to be left on disk substrate 10. This pattern includes generally concentric tracks in order to create the corresponding concentric tracks in the magnetic film. The disk as shown in Fig. 1C is then exposed through the mask. While layer 14 may also be a photoresist material, it is not necessary that it be radiation sensitive. Although it is preferred to optically expose layer 16 through a mask in order to improve the total processing time, it is also possible to use electron beam (E-beam) radiation to directly expose the desired pattern of photoresist layer 16. The E-beam exposure technique improves the resolution of the lithographic features. To further enhance the process speed, the mask technique may be changed to one where the source of illumination is a Synchrotron X-ray source, which provides resolution equivalent to serial single track exposure by an electron beam, and provides track exposure in parallel. After the photoresist layer 16 has been exposed, it is placed in a suitable developer, such as Shipley AZ-351. The developer dissolves the exposed photoresist layer 16, as well as portions of the chemically etchable layer 14, to create the structure shown in Fig. 1D, wherein concentric rings 20 of unexposed photoresist are supported above the magnetic film 12 by portions of support layer 14. Because the rate of development of the photoresist is known, as well as the rate of dissolution of the chemically etchable material in layer 14, it is possible to control the development step such that layer 14 dissolves in the areas beneath the side walls 24 of the rings 20 to form undercuts 27. In the preferred embodiment, both the portions of exposed photoresist layer 16 and the portions of support layer 14 between the side walls 24 of adjacent rings 20 and beneath the side walls 24 are removed in a single step which includes the development step of the photoresist layer 16. However, it is possible to first develop photoresist layer 16 and thereafter, in a separate step, remove suitable portions of layer 14 to create the structure shown in Fig. 1D. After the removal of the exposed portions of the photoresist layer 16 and the portions of the chemically etchable support layer 14, the disk is rinsed in distilled water and dried. The next step in the fabrication of the disk is the removal of the magnetic film 12 between side walls 24 of adjacent photoresist layer rings 20, as shown in Fig. 1E. In the preferred embodiment, the magnetic film is removed and the voids 31 created by sputter etching. The sputter etching is performed for a time sufficiently long to not only remove all of the magnetic film 12 between the side walls 24 of rings 20, but also a portion, e.g. 20nm, of the nickel-phosphorus surface film forming substrate 10. The additional sputter etching through the top of substrate 10 ensures that all of the magnetic material has been removed. The voids 31 can also be created by alternative techniques, such as ion milling or a wet chemical etch, such as etching in a ferric chloride solution. Following the removal of the magnetic film in the areas between the unexposed photoresist rings 20, a pattern of magnetic film results which creates discrete magnetic tracks 30 under the concentric rings 20 of unexposed photoresist. The disk is maintained in the same sputtering chamber and, without breaking vacuum, a film of nonmagnetic alumina (Al₂O₃) is sputter deposited into the voids 31 (Fig. 1E) to create nonmagnetic guard bands 32 between the magnetic tracks 30, as shown in Fig. 1F. The formation of the undercuts 27 (Fig. 1F) prevents "fencing" at the interface of the magnetic tracks 30 and the nonmagnetic guard bands 32. The alumina film is also deposited over the top surfaces 22 and portions of side walls 24 of the concentric rings 20 of unexposed photoresist. In the preferred embodiment, as shown in Fig. 1F, the alumina film 32 is deposited such that its top surface has a height slightly greater than the height of the magnetic tracks 30. The disk as shown in Fig. 1F is then removed from the sputtering chamber and placed in a suitable solvent, such as NMP (N-methyl2-pyrrolidone) or acetone. The solvent dissolves the remaining rings 20 of unexposed photoresist and the remaining portions of support layer 14, resulting in the disk structure shown in Fig. 1G. The disk structure of Fig. 1G comprises the substrate 10 with discrete magnetic tracks 30 separated by guard bands 32 which not only separate the magnetic tracks with nonmagnetic material, but also provide an elevated protective surface. Because the tracks 30 may be, for example, only 1 micron in radial dimension, which is significantly smaller than a single rail of an air bearing slider, the alumina guard bands 32 prevent damage to the magnetic tracks 30 in the event the slider contacts the disk surface. Following removal of the remaining photoresist and support layer 14, the disk is again rinsed in distilled water and dried and placed in the sputtering chamber for the deposition of additional alumina which is sputter deposited evenly over the entire surface of the disk. As shown in Fig. 1H, this results in an increased thickness of guard bands 32, as well as the placement of a passivation layer 33 of alumina over the magnetic tracks 30. Because the nonmagnetic material sputter deposited to form the guard bands 32 is identical to the material sputter deposited over the entire disk surface to provide the passivation of the magnetic tracks, the result is a continuous layer of nonmagnetic material which is formed on the substrate between the tracks and on top of the tracks. Because the magnetic tracks 30 cannot be contacted by the slider due to the elevation of the intermediate guard bands 32, the thickness of layer 33 of nonmagnetic material directly above the magnetic tracks 30 can be significantly less than if the elevated guard bands were absent. The layer 33 need be only thick enough to provide passivation of the cobalt-based alloy tracks 30 from the atmosphere. The disk structure shown in Fig. 1H, in addition to providing the benefits as previously described, also has the benefit of a textured overcoat. This substantially reduces the static friction (stiction) between the slider and the disk in those disk files in which the slider rests on the disk surface when the disk file is not operating. Referring now to Fig. 2A, there is shown an alternative disk structure to that shown in Fig. 1F. This disk structure is created by sputter depositing the alumina layer 32 to a thickness such that it has a top surface which is essentially coplanar with the top surface of magnetic tracks 30. Then, following removal of the remaining photoresist and support layer 14, additional alumina is sputter deposited over the entire disk surface. In this disk structure, the entire top surface of the disk over both the guard bands 32 and the magnetic tracks 30 is substantially planar. The thickness of the nonmagnetic layer 33 over the magnetic tracks 30 shown in Fig. 2B is sufficient to provide both passivation and protection from contact by the slider. While in the preferred embodiments of the resulting disk structures illustrated in Figs. 1H and 2B the nonmagnetic guard bands 32 and layer 33 over the magnetic tracks are a single continuous layer of nonmagnetic material, it is also possible to form a separate type of protective overcoat as a final sputter deposition step. Thus, the material sputter deposited over the entire disk surface to change the disk from that depicted in Fig. 1G to that depicted in Fig. 1H may be a different type of nonmagnetic material. In addition to alumina, any other type of nonmagnetic material known to have passivating and/or wear-resistant properties may be selected. Examples of such materials are oxides, for example, silicon dioxide or zirconium oxide, amorphous carbon, amorphous hydrogenated carbon and various carbides or nitrides.

Claims: A method of making a discrete track magnetic record disk comprising the steps of: forming a continuous film (12) of magnetic metal or oxide on a disk substrate (10); forming a support layer (14) of chemically etchable material on the magnetic film; forming a layer (16) of photoresist on the support layer; exposing selected regions of the photoresist layer to radiation; developing the photoresist layer to define a predetermined pattern of unexposed photoresist over the magnetic film, said pattern including concentric rings (20) having side walls (24) oriented generally perpendicularly to the disk substrate; removing the support layer material from areas between the concentric rings of the unexposed photoresist and from beneath the side walls of the concentric rings of the unexposed photoresist; removing the magnetic film in areas not patterned by the unexposed photoresist so as to leave magnetic metal or oxide on the substrate, the remaining magnetic metal or oxide defining a pattern of concentric tracks (30) corresponding to the pattern of concentric rings (20) of unexposed photoresist; refilling the voids (31) created by the removal of the magnetic metal or oxide with nonmagnetic material to at least the height of the magnetic tracks; and removing the remaining photoresist and the remaining support layer material. A method as claimed in claim 1, wherein the photoresist layer is developed and the support layer material removed by the single step of subjecting the photoresist layer and the support layer to a developer in which the support layer is soluble. A method as claimed in claim 1 or claim 2, further comprising forming a protective overcoat over the magnetic alloy or oxide tracks and the nonmagnetic material after the removal of the remaining photoresist and the remaining support layer material. A method as claimed in claim 3, wherein the overcoat is formed by depositing material identical to the nonmagnetic material used to refill the voids. A method as claimed in any preceding claim, wherein the voids are refilled to a height substantially equal to that of the magnetic alloy or oxide tracks, whereby the surface of the completed disk is substantially planar. A method as claimed in any of claims 1 to 4, wherein the voids are refilled to a height slightly higher than that of the magnetic alloy or metal oxide tracks. A method as claimed in any preceding claim, wherein the areas of the magnetic film are removed by sputter etching and wherein the voids are refilled by sputter depositing the nonmagnetic material immediately after the sputter etching step without breaking vacuum. A method as claimed in any preceding claim, wherein the exposing of the selected regions of the photoresist layer comprises the steps of: providing a mask having a radiation-opaque pattern including concentric tracks; and directing radiation through the mask to expose the photoresist. A method as claimed in any of claims 1 to 7, wherein the selected regions of the photoresist layer are directly exposed with an E-beam. A method as claimed in any preceding claim, wherein the magnetic film consists of a cobalt-based alloy. A method as claimed in any of claims 1 to 9, wherein the magnetic film consists of chromium or a chromium alloy. A method as claimed in any preceding claim, wherein the nonmagnetic layer used to refill the voids consists of amorphous carbon. A method as claimed in any of claims 1 to 11, wherein the nonmagnetic layer used to refill the voids consists of alumina. A discrete track thin film magnetic record disk for use in a disk file of the type wherein an air-bearing slider supports a read/write head, the disk comprising: a plurality of discrete concentric tracks (30) of magnetic metal or oxide formed on a substrate, the top surfaces of the discrete tracks being substantially coplanar; and a continuous layer of nonmagnetic material formed over the top surfaces of the tracks and over the substrate between the tracks, the height of the continuous layer in the regions between the tracks being at least as high as that in the regions on top of the tracks. A disk as claimed in claim 14, wherein the layer of nonmagnetic material is higher in the regions between the tracks than in the regions on top of the tracks, whereby the tracks are protected from contact by the slider.

Inventors: KROUNBI MOHAMAD TOWFIK, PATLACH ALVIN MURRAY, SANDERS IAN LEWIS, KROUNBI, MOHAMAD TOWFIK, PATLACH, ALVIN MURRAY, SANDERS, IAN LEWIS
Applicants: IBM, INTERNATIONAL BUSINESS MACHINES CORPORATION
Application year: 1989
Main classification: G11B5
IPC codes: G11B5