Abstract:
A method for shaping an ABS of a magnetic head slider including a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to an adhesive or UV tape capable of passing a laser beam there through, the first surface being opposite an ABS of the at least one row bar, a step of shaping the ABS of the at least one row bar in a convex shape by radiating a laser beam to the first surface of the at least one row bar through the adhesive or UV tape, a step of cutting the at least one row bar into individual magnetic head sliders, and a step of then, removing the magnetic head sliders from the adhesive or UV tape after weakening adhesion properties of the adhesive or UV tape.

Description:
This application is a divisional application of U.S. patent application Ser. No. 10/143,951, filed May 14, 2002 now U.S. Pat. No. 6,865,798. 

   FIELD OF THE INVENTION 
   The present invention relates to a method for finally shaping an air beaming surface (ABS) of a magnetic head slider and a manufacturing method of a magnetic head slider using this shaping method. 
   DESCRIPTION OF THE RELATED ART 
   A flying magnetic head slider with a thin-film magnetic head is required to have a slightly convex shape such as convex crown and/or camber in an ABS of each rail in order to obtain an excellent flying performance. The “crown” represents a deformation in shape along fore-and-aft directions of the magnetic head slider or directions in parallel with an air-flowing direction, and the “camber” represents a deformation in shape along lateral directions of the magnetic head slider or directions perpendicular to the air-flowing direction. In some cases, the crown and the camber may be generically called as the crown. 
   The ABS with such convex shape is formed in a final shaping work after various works for a row bar provided with a plurality of aligned magnetic head sliders. Namely, in this final work the ABS is shaped to be convex by radiating a laser beam to a surface opposite to the ABS of the row bar so as to intentionally deform this row bar (U.S. Pat. No. 5,266,769). 
   However, in the conventional final shaping work because the row bar is caught by a jig for holding, chipping of the row bar or contamination thereof may occur. 
   Also, if the row bar is cut and separated into individual magnetic head sliders after the shaping of the ABS to be convex, the convex ABS may be deformed because of a distortion produced during the cutting. Thus, a desired flying performance cannot be expected. 
   If the shaping of the ABS to be convex is executed after the cutting of the row bar into individual magnetic head sliders, the latter problem will not occur. However, in this case, a positioning of each magnetic head slider for the convex shaping and a measurement of a crown amount or a height of the crest from the root of the convex shape are very difficult. Particularly, in the case of a downsized magnetic head slider referred to as a 30% slider with a size of 1.0 mm×1.235 mm×0.3 mm or a 20% slider with a size of 0.7 mm×0.85 mm×0.23 mm, it is quite difficult to easily and accurately execute the positioning of each magnetic head slider and the measurement of a crown amount. As will be noted, during or after the shaping of the ABS into convex, it is required to measure the crown amount to control a shaping amount. 
   SUMMARY OF THE INVENTION 
   It is therefore an object of the present invention to provide a method for finally shaping an ABS of a magnetic head slider and a manufacturing method of a magnetic head slider using this shaping method, whereby occurrence of chipping and contamination of the magnetic head slider can be reduced. 
   Another object of the present invention is to provide a method for finally shaping an ABS of a magnetic head slider and a manufacturing method of a magnetic head slider using this shaping method, whereby an ABS of the magnetic head slider can be easily and accurately shaped into a desired convex shape. 
   According to the present invention, a method for shaping an ABS of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to an adhesive tape capable of passing a laser beam there through, the first surface being opposite an ABS of the at least one row bar, a step of shaping the ABS of the at least one row bar in a convex shape by radiating a laser beam to the first surface of the at least one row bar through the adhesive tape, a step of cutting the at least one row bar into individual magnetic head sliders, and a step of then removing the magnetic head sliders from the adhesive tape after weakening adhesion properties of the adhesive tape by, for example, heating the tape. 
   Because the shaping of the ABS of the row bars is executed while the row bars are adhered and held by the adhesive tape, no chipping of the row bars nor contamination thereof can occur. 
   It is preferred that the cutting step includes cutting at least one row bar into individual magnetic head sliders so that the adhesive tape holds all of the individual magnetic head sliders. It is also preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Because a crown amount of the magnetic head slider is measured under a state in which all the sliders are held by the adhesive tape, a precise measurement can be extremely easily performed. 
   It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the adhesive tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the adhesive tape. 
   Also, according to the present invention, a method for shaping an air bearing surface of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to an adhesive tape capable of passing a laser beam therethrough, the first surface being opposite to an ABS of the at least one row bar, a step of cutting the at least one row bar into individual magnetic head sliders so that the adhesive tape holds all of the individual magnetic head sliders, a step of shaping an ABS of the individual magnetic head slider in a convex shape by radiating a laser beam to the first surface of the magnetic head slider through the adhesive tape, and a step of then, removing the magnetic head sliders from the adhesive tape after weakening adhesion properties of the adhesive tape. 
   Because the shaping of the ABS of the row bars is executed while the row bars are adhered and held by the adhesive tape, no chipping of the row bars nor contamination thereof can occur. In addition, because the convex shape is formed after cutting into the individual magnetic head sliders, no deformation in crown resulting from distortion that may occur during the dicing process of the row bar into the individual magnetic head sliders will be produced. Also, because all the magnetic head sliders are held in the fixing state to the adhesive tape, the positioning of each magnetic head slider for the convex shaping can be precisely and easily performed. 
   It is preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Because a crown amount of the magnetic head slider is measured under the state where all the sliders are held by the adhesive tape, a precise measurement can be extremely easily performed. 
   It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the adhesive tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the adhesive tape. 
   According to the present invention, further, a method for shaping an ABS of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to a UV tape capable of passing a laser beam there through, the first surface being opposite an ABS of the at least one row bar, a step of shaping the ABS of the at least one row bar into a convex shape by radiating a laser beam to the first surface of the at least one row bar through the UV tape, a step of cutting the at least one row bar into individual magnetic head sliders, and a step of then removing the magnetic head sliders from the UV tape after radiating an ultra violet light to the UV tape so as to weaken its adhesion properties. 
   Because the shaping of the ABS of the row bars is executed while the row bars are adhered and held by the UV tape, no chipping of the row bars nor contamination thereof can occur. 
   It is preferred that the cutting step includes cutting at least one row bar into individual magnetic head sliders so that the UV tape holds all of the individual magnetic head sliders. It is also preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Because a crown amount of the magnetic head slider is measured under the state where all the sliders are held by the UV tape, a precise measurement can be easily performed. 
   It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the UV tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the UV tape. 
   Also, according to the present invention, a method for shaping an ABS of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to a UV tape capable of passing a laser beam therethrough, the first surface being opposite an ABS of the at least one row bar, a step of cutting the at least one row bar into individual magnetic head sliders so that the UV tape holds all of the individual magnetic head sliders, a step of shaping an ABS of the individual magnetic head slider into a convex shape by radiating a laser beam to the first surface of the magnetic head slider through the UV tape, and a step of then removing the magnetic head sliders from the UV tape after radiating an ultra violet light to the UV tape so as to weaken its adhesion properties. 
   Because the shaping of the ABS of the row bars is executed while the row bars are adhered and held by the UV tape, no chipping of the row bars nor contamination thereof are occurred. In addition, because the convex shape is formed after cutting into the individual magnetic head sliders, no deformation in crown resulting from distortion that may occur during the dicing process of the row bar into the individual magnetic head sliders will be produced. Also, because all the magnetic head sliders are held in the fixing state to the UV tape, the positioning of each magnetic head slider for the convex shaping can be easily performed. 
   It is preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Because a crown amount of the magnetic head slider is measured under the state where all the sliders are held by the UV tape, a precise measurement can be easily performed. 
   It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the UV tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the UV tape. 
   Further, according to the present invention, a manufacturing method of a magnetic head slider includes a step of dicing an wafer on which many of thin-film magnetic head elements are fabricated to obtain a plurality of row bars each having a plurality of aligned thin-film magnetic head elements, a step of forming ABSs of magnetic head sliders on one surface of the each row bar, and the above-mentioned steps for shaping the ABS of each magnetic head slider. 
   Further objects and advantages of the present invention will be apparent from the following description of the preferred embodiments of the invention as illustrated in the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows an oblique view schematically illustrating an example of a magnetic head slider fabricated by a manufacturing method according to the present invention; 
       FIG. 2  shows a sectional view seen from an A—A line of  FIG. 1 ; 
       FIG. 3  shows a sectional view seen from a B—B line of  FIG. 1 ; 
       FIG. 4  shows a flow chart schematically illustrating a manufacturing method of a magnetic head slider as a preferred embodiment according to the present invention; 
       FIG. 5  shows an oblique view illustrating an adhering step of a row bar to a UV tape; 
       FIG. 6  shows an oblique view illustrating an example of a fixing jig on which a UV tape with a plurality of row bars is attached; 
       FIG. 7  shows a sectional view seen from a C—C line of  FIG. 6 ; 
       FIG. 8  shows a sectional view of the fixing jig mounted on a laser radiation device; 
       FIG. 9  shows a sectional view of the fixing jig mounted on a cutter device; 
       FIGS. 10   a  and  10   b  show sectional views illustrating the row bar adhered on the UV tape before cutting and after cutting; and 
       FIG. 11  shows a flow chart schematically illustrating a manufacturing method of a magnetic head slider as another embodiment according to the present invention. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1  schematically illustrates an example of a magnetic head slider fabricated by a manufacturing method according to the present invention,  FIG. 2  is a sectional view seen from an A—A line of  FIG. 1 , and  FIG. 3  is a sectional view seen from a B—B line of  FIG. 1 . 
   In  FIG. 1 , reference numerals  11  and  12  denote two side rails of a flying type magnetic head slider  10 ,  13  denotes a rear rail of the magnetic head slider  10 ,  14  denotes slider ABSs formed on surfaces of the side rails  11  and  12  and the rear rail  13  of the slider,  15  denotes a thin-film magnetic head element partially appeared on the ABS of the rear rail  14 , and  16 – 19  denote electrode terminals electrically connected to the magnetic head element  15 , respectively. 
   As slightly exaggerated for purposes of illustration in  FIGS. 2 and 3 , the magnetic head slider  10  is worked to have a slightly convex shape such as convex crown and/or camber in the ABS  14  of each rail in order to obtain an excellent flying performance. 
     FIG. 4  schematically illustrates a manufacturing method of a magnetic head slider as a preferred embodiment according to the present invention. Hereinafter, a method for shaping an ABS of the magnetic head slider into a convex shape and a manufacturing process of the magnetic head slider will be described with reference to the figure. 
   First, many magnetic head elements arranged in a matrix are fabricated on a wafer by using a thin-film fabrication technique (step S 1 ). This wafer process for fabricating the thin-film magnetic head elements can be performed by using various known methods. 
   Then, the wafer is cut into a plurality of row bars each of which has a plurality of aligned thin-film magnetic head elements (step S 2 ). 
   Then, the plurality of row bars are adhered and fixed to a UV tape (step S 3 ). This adhesion is performed by adhering a surface opposite the ABS of the row bar to the UV tape. The UV tape has, in general, a three-layer structure of a base film, a UV-curing adhesive layer that will be cured by radiation of an ultra violet light and a peel-off film. As shown in  FIG. 5 , first, the peel-off film  50   a  is removed from the UV tape  50  and then the row bars  51  are stuck to the exposed adhesive layer  50   b . It is important to press the UV tape against the stuck row bars so that air bubbles remain between the row bars and the UV tape. 
   Next, the UV tape  50  with the stuck row bars  51  is attached to a fixing jig used for a laser radiation process and a cutting or dicing process (step S 4 ). 
     FIG. 6  illustrates an example of this fixing jig with the attached UV tape, and  FIG. 7  is a sectional view seen from a C—C line of  FIG. 6 . 
   As shown in these figures, the fixing jig  60  consists of a base frame  61  shaped in a circular loop, for example, and a cover frame  62  also shaped in the circular loop and used in contact with the base frame  61 . The fixing jig  60  holds or supports the UV tape  50  with the stuck row bars  51  by pinching the margins of the UV tape  50  between the base frame  61  and the cover frame  62 . Thus, the rowbars  51  will be tightly supported by the stretched UV tape  50 . 
   Then, the fixing jig  60  is mounted on a laser radiation device and a laser beam is radiated to surfaces opposite the ABSs of the row bars via the UV tape (step S 5 ). 
     FIG. 8  illustrates the fixing jig  60  mounted on a table of the laser radiation device and the row bars  51  to which the laser beam is applied from rear side of the UV tape  50 . Tackiness or adhesion properties of the adhesive layer of the UV tape  50  will not change even if the laser beam is radiated. The UV tape  50  will not absorb the laser beam but it will instead pass there through and therefore the radiated laser beam will be applied to the surface of the row bars  51 , which is opposite the ABS. By applying the laser beam to only the surface opposite the ABS, this surface is partially and momentarily heated and melted to produce a stress in this surface only. Therefore, there occurs a difference in stresses between the opposite surface and the ABS, and then a convex shape such as a convex crown and/or camber shown in  FIGS. 2 and 3  is formed in each row bar. 
   Any kind of laser source can be used if it is possible to partially heat and melt the rear surface of the row bar. In the case in which the laser beam is a spot beam with a small diameter, the laser beam will be moved to scan the row bars in longitudinal directions, lateral directions or slanting directions. In case of a relatively large diameter laser beam, these row bars will be radiated all at once. 
   Thereafter, the fixing jig is detached from the laser radiation device and then mounted on a dicing device, so that each row bar is cut and separated into individual magnetic head sliders (step S 6 ). 
     FIG. 9  illustrates the fixing jig  60  mounted on a working table  90  of the dicing device. The working table  90  has a vacuum chuck  93  with a porous chuck  91  and a vacuum chamber  92 . The fixing jig  60  is attached on this working table  90  and the rear surface of the UV tape  50  is sucked through the porous chuck  91  to uniformly support the entire area of the UV tape. Under this state, the row bar  51  is cut and separated into individual magnetic head sliders. 
     FIGS. 10   a  and  10   b  illustrate the row bar  51  adhered on the UV tape  50 .  FIG. 10   a  indicates the row bar prior to cutting and  FIG. 10   b  indicates the row bar after cutting. As shown in  FIG. 10   b , when cutting the row bar  51 , the UV tape  50  will not completely cut along its thickness but a part of the UV tape will remain connected Thus, all the magnetic head sliders  101  will be held in a fixing state to the fixing jig  60  through the UV tape  50 . 
   Then, if necessary, a crown amount of each magnetic head slider is measured (step S 7 ). The crown amount that corresponds to a height of the crest from the root of the convex shape in the ABS of the magnetic head slider will be optically measured. In order to execute this measurement, it is required that each magnetic head slider is precisely positioned on a measurement stage without inclining. In this embodiment, because all the magnetic head sliders are held in the fixing state to the UV tape, the positioning will be automatically completed and therefore extremely easy and precise measurement of the crown amount can be expected. This is, in particular, advantageous for a downsized magnetic head slider such as a 20% slider or a 30% slider. Also, because a crown amount of each magnetic head slider, and not a crown amount of each row bar, can be measured, influence of a distortion that might occur during the dicing process of the row bar into the individual magnetic head sliders can be omitted from the measured amount. Furthermore, because of using of a thin UV tape with a thickness of about 100 μm, a distortion that may be produced at adhesion of the row bars to this UV tape will be absorbed by the UV tape itself and the magnetic head slider will be unaffected by the possible distortion. As a result, a flatness of the ABS will not change before and after the adhesion and, thus, a precise crown amount can be measured. 
   Thereafter, an ultraviolet light is radiated to the rear surface of the UV tape  50  to cure the adhesion layer of this UV tape (step S 8 ). 
   As a result of the curing of the adhesion layer, the adhesion properties of the UV tape will be weakened, and then the magnetic head sliders  101  are detached from the UV tape  50  (step S 9 ). 
   As aforementioned, according to this embodiment, because the shaping of the ABS of the row bars are executed while the row bars is adhered and held by the UV tape, no chipping of the row bars nor contamination thereof can occur. Also, because a crown amount is measured under this state, a precise measurement can be extremely easily performed. 
     FIG. 11  schematically illustrates a manufacturing method of a magnetic head slider in another embodiment according to the present invention. In this embodiment, a dicing process of row bars is carried out before a laser radiation process. Hereinafter, a method for shaping an ABS of the magnetic head slider into a convex shape and a manufacturing process of the magnetic head slider will be described with reference to the figure. 
   First, many magnetic head elements arranged in matrix are fabricated on an wafer by using a thin-film fabrication technique (step S 11 ). 
   Then, the wafer is cut into a plurality of row bars, each of which has a plurality of aligned thin-film magnetic head elements (step S 12 ). 
   Then, the plurality of row bars are adhered and fixed to a UV tape (step S 13 ). 
   Next, the UV tape  50  with the stuck row bars  51  is attached to a fixing jig used for a cutting or dicing process and a laser radiation process (step S 14 ). 
   Then, the fixing jig  60  is mounted on a dicing device, so that each row bar is cut and separated into individual magnetic head sliders (step S 15 ). 
   Thereafter, the fixing jig is detached from the dicing device, and then mounted on a laser radiation device. A laser beam is radiated to surfaces opposite to the ABSs of the row bars via the UV tape (step S 16 ). By applying the laser beam to only the surface opposite to the ABS, this surface is partially and momentarily heated and melted to produce a stress in this surface only. Therefore, there occurs a difference in stresses between the opposite surface and the ABS, and then a convex shape, such as, a convex crown and/or camber, is formed in each row bar. In this embodiment, because the convex shape is formed after cutting into the individual magnetic head sliders, no deformation in crown due to a distortion that may occur during the dicing process of the row bar into the individual magnetic head sliders will be produced. 
   Then, if necessary, a crown amount of each magnetic head slider is measured (step S 17 ). 
   Thereafter, an ultraviolet light is radiated to the rear surface of the UV tape  50  to cure the adhesion layer of this UV tape (step S 18 ). 
   As a result of the curing of the adhesion layer, the adhesion properties of the UV tape will be weakened, and then the magnetic head sliders  101  are detached from the UV tape  50  (step S 19 ). 
   Other Processes, operations and advantages in this embodiment are the same as those in the embodiment of  FIG. 4 . 
   In the aforementioned embodiments, the execution order of the process of step S 3  or S 13  and the process of step S 4  or S 14  may be inversed each other, namely, row bars may be adhered to a UV tape after the UV tape is attached to a fixing jig. 
   Also, instead of the UV tape, any adhesive tape that passes a laser beam there through and has adhesion properties weakened by heating may be used. In this case, similar processes, except that a heating process is performed in place of the ultra violet light radiation process, will be carried out and similar advantages will be obtained. 
   Many widely different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in the specification, except as defined in the appended claims.