Abstract:
Defects of a hard disk drive servo pattern stamper are detected by comparing a scattered light beam pattern against the known servo pattern. A magnetic field is applied to stamper and the beam is linearly polarized. Variations in the physical offset of the beam, its scatter, are indicative of physical defects. Variations in the Kerr rotation of scattered beam are indicative of magnetic defects.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims benefit of U.S. provisional patent application serial No. 60/392,788, filed on Jun. 28, 2002, which is hereby incorporated by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The invention relates to field of disk drives and more particularly to methods for writing servo tracks on magnetic hard disks.  
           [0004]    2. Description of Related Art  
           [0005]    Hard disk drives provide prerecorded tracking servo information on the data recording surfaces of their magnetic hard disks. This servo information typically comprises servo bursts spaced evenly along tracks. Data is recorded between the servo bursts. In most cases, servo bursts are approximately radially aligned, describing a small arc from the disk&#39;s ID to its OD. This radial alignment makes them look like arced spokes of the wheel. They are made to form and arc because the servo data is read by a rotary actuator that describes the same arc because the traverses between a disk&#39;s ID and its OD.  
           [0006]    [0006]FIG. 1 illustrates a disk  10  having a number of servo data spokes  12 . While there are eight illustrated in the figure, a typical disk drive disk will typically have hundreds of such servo data spokes spaced it even angles around disk. The number of such servo data spokes depends upon the track density. As a general rule, the greater the number of spokes, the higher the track density that can be employed in the disk drive. In many disk drives today, the servo data takes up approximately 11 percent of the total disk drive recording surface.  
           [0007]    The servo bursts may be written onto a disk&#39;s surface using a variety of techniques. The most common method is to write the servo onto the disk using the disk drive&#39;s own magnetic head controlled typically by an externally introduced picker that grasps the drive&#39;s rotary actuator arm upon which the read/write head is mounted. An external mechanism incrementally moves the arm while other circuits command the disk drive to write the servo bursts.  
           [0008]    Another common servo-writing method comprises writing servo bursts onto the disks already assembled onto the disk drive spindle but prior to the disk drive spindle/disk combination, also known as a hub/disk assembly (“HDA”), being assembled into the disk drive itself.  
           [0009]    A newer approach employs a stamper to “print” the servo patterns on the disk using a high permeability stamper, as illustrated in FIG. 2, to impose a pattern on media. As illustrated in the top leftmost portion of the figure, the disk is first DC erased. For example, an externally applied field, the large arrows H in the figure, causes all the magnetic domains  14  of the media to switch in an uniform direction as illustrated. Next, a high permeability stamper  16 , having a desired pattern  17 , is pressed against the disk  10 . An externally applied field of opposite polarity, illustrated by the now downward arrows, is now applied to the disk through the stamper  16 . This causes the disk areas in contact with the stamper  16  to switch their magnetic direction to be aligned with the externally applied field. The areas not in contact with the stamper are shielded by the stamper. The shielded areas do not changed their magnetic orientation. This causes the disk to assume a reversed magnetic orientation  15  in the pattern  17  of the stamper  16 .  
           [0010]    While FIG. 2 illustrates vertically oriented magnetic domains  14  and  15  which are useful in perpendicular recording, the same technique may be employed using horizontally oriented magnetic fields to encode horizontally oriented magnetic domains.  
           [0011]    The stamper  16  appears identical to FIG. 1 when viewed from a plan view. In other words, the stamper  16  would encode the images of the servo bursts radially aligned in arced spokes as illustrated in FIG. 1.  
           [0012]    A problem that occurs in writing servo onto a disk regardless of the technique used is that the disk drives can tolerate only so much servo error before servo must be rewritten or the disk scrapped. Most drives cannot, for example, tolerate two bad servo bursts in a row.  
           [0013]    Today&#39;s disk drive manufacturing processed, therefore, typically check the quality stampers servo data patterns before the stamper is used to print servo data onto a disk.  
           [0014]    There are three conventional methods for inspecting stampers for servo defects:  
           [0015]    1. manual visual inspection;  
           [0016]    2. atomic force microscopy (“AFM”); and  
           [0017]    3. optical microscopy.  
           [0018]    The problem with the first method is that it is to manually labor-intensive. The problem with us the last two methods are that they are too time-consuming. Better and faster methods to test stampers are needed.  
         SUMMARY OF THE INVENTION  
         [0019]    The invention comprises detecting defects embedded in servo patterns on a magnetic hard disk servo pattern stamper using scattered light. The defects may be physical defects, magnetic defects or both. A beam is scanned across a servo pattern on a stamper. The scattered beam is detected and then compared to the servo pattern to identify defects. Physical defects cause offsets in the scattered beam. Magnetic defects cause unexpected Kerr rotation. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    [0020]FIG. 1 is an illustration of the arced spoke patterns of servo data on a magnetic hard disk.  
         [0021]    [0021]FIG. 2. illustrates a method for recording magnetic marks onto the disk using a high permeability stamper.  
         [0022]    [0022]FIG. 3 illustrate the detection of physical stamper defects using scattered light.  
         [0023]    [0023]FIG. 4 illustrates the detection of magnetic stamper defects using scattered light and Kerr rotation. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0024]    [0024]FIG. 3 illustrates an apparatus for detecting physical defects on a hard disk servo pattern stamper. In the Fig., stamper  16  has embossed on at least one surface thereof a servo pattern consisting of raised surfaces  17 . The servo pattern may have physical defects. A first kind of physical defect is a dropout  34 . A dropout consists of a missing embossed pattern, i.e., an empty space appears where the servo pattern would call for stamper to have an embossed raised feature. This is illustrated by the dotted line  34  in the figure indicating the absence of embossed feature. This is a dropout.  
         [0025]    The second kind of physical defect is debris  36 . Debris  36  may be lodged onto the stamper  16  in area of the servo pattern  17 . Debris not only causes the false recording of a servo “pattern” on the magnetic hard disk, the debris may cause physical damage to the disk.  
         [0026]    Referring again to FIG. 3, a light source  30  emits a beam of light  31  which reflected by the stamper at point  33 , for example, to a reflected beam  35 , which is then turned detected by light detector  32 , which may also conduct the comparison of the received pattern to the expected pattern, or may pass the data onto a computer (not shown) for this purpose. The beam may be of any kind of light of sufficiently small wavelength so that it does not have a significant amount of diffractive interference with the servo pattern. The light source is preferably a laser.  
         [0027]    The angle of reflection of the reflected beam  35  is equal to the angle of incidence of the incident beam  31 . Thus the reflected beam will have offset  37  at the detector  32  depending and whether the beam strikes the surface  18  of the stamper or one of the embossed features  17  of the servo pattern. The dashed line  38  indicates the path of the reflected beam had it struck an embossed feature  34 , which is also drawn as a dotted line to indicate a dropout.  
         [0028]    The offset  37  may also occur when the beam  30  strikes debris  36  instead of the stamper surface  18  or embossed features  17 .  
         [0029]    In order to detect physical defects in the servo pattern, the beam must be scanned across the servo pattern on the stamper while the optical detector  32  detects the reflected beam, which can either be the beam  35  reflected from the surface  18  of the stamper or the beam  38  reflected from an embossed feature  17  of the stamper (or debris). By comparing the scanned beam against a known servo pattern, the differences between patterns will be indicative of the presence of physical defects in the pattern. The locations of these defects can then be mapped for subsequent verification by the use of AFM or optical microscopy, for example.  
         [0030]    A scan may comprise any of the following: rotating a stamper on a spinstand (optional) under the optical detector ( 30 ,  32 ) in combination with indexing the detector radially, using an X-Y positioner (not shown), scanning the beam  30  itself, or any combination of these. If the beam itself is scanned, the angle of incidence will correspondingly change. This must be compensated for in the detection algorithm.  
         [0031]    [0031]FIG. 3 illustrates a beam size much smaller than the size of servo patterns being observed. If, however, the beam size (spot size) is much larger, for example, larger even then the size of the servo patterns being detected, the physical offsets in the reflected beam may be detected by the optical detector  32  in the form of amplitude variations. The amplitude variations may be so small that individual servo patterns  17 ,  18  or defects  34  or  36  cannot be detected. Under these circumstances, defects in the servo patterns may be detected by using pattern recognition techniques. For example, the a known good stamper servo pattern may be scanned one or more times to form a reference pattern of the amplitude density of the detected beam. The pattern detected from a scan of a stamper under test may then be compared to this reference pattern. Statistically significant variations between the two patterns indicate the presence of defects.  
         [0032]    A preferred statistical technique for detecting these differences is to use a statistical measurement known as Kurtosis. Kurtosis is a measure of peakedness of an amplitude density curve. This measurement is highly sensitive to peaks and valleys because it employs the fourth power of deviations from a mean or baseline signal. The statistical formula for Kurtosis is  
           R   ku     =         1     R   q   4            1   N            ∑     j   =   1     N            Z   j   4                   where                   R   q           =       R                 MS     =         1   N            ∑     j   =   1     N          Z   J   2                 ,   and                         
 
         [0033]    Z is the distance from a baseline signal for a sample j.  
         [0034]    For example, if a beam spot size is on the order of six microns and it is used to scan a servo burst or spoke 50 microns in length, the scanning system may take samples at 5 micron increments. The entire spoke may be scanned with only nine samples. Each of these samples would have an amplitude distance Z from an amplitude baseline signal. The Kurtosis value for the servo burst or spoke could be calculated and then compared to a reference Kurtosis value computed from signal generated by a known good servo pattern. If the deviation, for example, exceeded a predetermined value indicative of the presence or absence of a defect, the particular bad servo burst or spoke may be flagged for later inspection by more sensitive equipment such as atomic force microscopes.  
         [0035]    Alternatively, the Kurtosis value may be calculated for every servo burst or spoke on a track. If the deviation, for example, exceeded a predetermined value indicative of the presence or absence of a defect somewhere on a track, the particular bad track may be flagged for later inspection by more sensitive equipment.  
         [0036]    Referring to FIG. 4, magnetic defects in the stamper may be detected by the use of Kerr rotation. Magnetic defects comprise areas of the stamper having reduced or no permeability such that that even if the stamper does not have a physical defect, it still would not print the desired servo pattern because of its failure to conduct enough of the external magnetic field to the magnetic hard disk. Alternatively, the small particles can adhere to the servo pattern. If the particles are non magnetic, they will reduced the effective permeability at the location of the particle. If they are magnetic, they will cause increased magnetization at the location of the particle. In either case, they may be detected through Kerr rotation.  
         [0037]    In the figure, a source of magnetic field such as electromagnetic  48  applies a magnetic field to the stamper  16  from one side thereof. A Kerr rotation optical detector ( 40 ,  42 ,  47  and  49 ) is mounted facing the other side of the stamper  16 . The Kerr rotation optical scanner consists of a light source  40 , preferably a laser beam  41 . This beam passes through a polarizer  47 , which preferably may be a linear polarizer. This beam  41  strikes the stamper at a point  43  where it is reflected through a polarization analyzer  49  and is then detected by and optical detector  42 . When the beam strikes the surface of the stamper  16 , it&#39;s polarization is rotated slightly by a phenomenon known as Kerr rotation. The polarizing analyzer  49  transmits the beam  45  depending upon it&#39;s polarization. Thus the level of transmission will depend upon the polarization of the reflected beam  45 . This difference in beam intensity may be detected by the optical detector  42 , which may also conduct the comparison of the received pattern with the expected pattern, or pass the data onto a computer (not shown) for this purpose.  
         [0038]    As discussed above the connection with FIG. 3, the magnetic defects in the servo pattern may be determined by scanning the beam across the servo patterns, detecting reflected beam intensity and comparing it is to the pattern expected. The differences between the intensity of the reflected beam and the expected intensity are caused by magnetic defects. In particular, a statistical representation of a the Kerr rotation signals measured from a good pattern may be formed into a reference pattern. A preferred statistical representation is the Kurtosis of at least one servo spoke on a track. Alternatively, the statistical representation may be the Kurtosis of all servo spokes on a track.  
         [0039]    As before, the scan may be affected by rotating the stamper and radially indexing the optical detector, by moving stamper on and X-Y positioner, by scanning the beam itself, or by any combination of these.  
         [0040]    While either of the aforementioned techniques may be used independently of each other, they are preferably combined. Thus the detector is preferably adapted to detect both offsets in the reflected beam indicative of physical defects and also is adapted to detect variations in the Kerr rotation of the reflected beam. The apparatus for doing so will look very much like the apparatus depicted in FIG. 4. The optical detector  40  would also be additionally sensitive to the beam offsets  37  from FIG. 3. With a combined apparatus, a single scan of the stamper will detect both physical and magnetic defects.  
         [0041]    The description of the preferred apparatus may be varied by those ordinary skill as appropriate and should not be taken as a limitation on the scope of the pending claims.