Method of manufacturing head gimbal assemblies, actuators and disk drives by removing thermal pole-tip protrusion at the spin stand level

Abstract

Thermal pole tip protrusion is caused by the materials in and around the head slider expanding during write operations till part of those materials protrude, leading to contact with the rotating disk surface, altering the flying height and often wearing down part of the disk surface. While it is well known that read-write heads expand during writing, the inventors are unaware of anyone else who recognized this situation's significance, particularly as the flying height decreases and the data rates increase, both of which are required for high areal density disk drives. The inventors realized that they could detect the problem at the spin stand level by testing head gimbal assemblies to reliably, and inexpensively, predict the tendency for thermal pole tip protrusion. This leads to selection of head gimbal assemblies, which do not have the thermal pole tip protrusion tendency. The selected head gimbal assemblies have better reliability, as do actuators and disk drives made with the selected head gimbal assemblies.

1 . A head gimbal assembly as a product of the process comprising the steps: 
 estimating a thermal pole tip protrusion tendency for said head gimbal assembly containing a read-write head; and    selecting said head gimbal assembly whenever said head gimbal assembly does not have said thermal pole tip protrusion tendency;    said method comprising, for each member of a track collection, the step of:    determining said thermal pole tip protrusion tendency for said head gimbal assembly on said track collection member; and    said method, further comprising the step of:    predicting said thermal pole tip protrusion for said head gimbal assembly based upon, for each of said track collection members, said thermal pole tip protrusion tendency on said track collection member;    wherein said track collection is comprised of an inside diameter track of a disk surface and an outside diameter track of said disk surface;    wherein said read-write head provides a magneto-resistance from a disk surface while performing a write operation to said track collection member on said disk surface and provides a voltage while reading said track collection member at a bias current, for each of said track collection members;    wherein said disk surface rotates at a rotational frequency;    wherein the step determining said thermal pole tip protrusion tendency is comprised of at least one member of the collection comprising the steps of:    monitoring a change of said magneto-resistance while said read-write head performs said write operation of said track collection member to determine said thermal pole tip protrusion tendency;    wherein the step monitoring said change is further comprised of:    observing said magneto-resistance while said read-write head performs said write operation on said track collection member to create a sudden MRR change event collection and to create a MRR value;    determining a number of said sudden MRR change event collection members;    determining a change characteristic based upon an amount MRR change divided by said MRR value, for each of said sudden MRR change event collection members; and    determining said thermal pole tip protrusion tendency based upon said number of said sudden MRR change event collection members and based upon said change characteristic for said sudden MRR change event collection members.    
   
   
       2 . The head gimbal assembly of  claim 1 , 
 wherein said track collection is further comprised of a middle diameter track of said disk surface.    
   
   
       3 . A method of making an actuator, comprising the step of: assembling said actuator using at least one of said head gimbal assemblies of  claim 1 .  
   
   
       4 . Said actuator as a product of the process of  claim 3 .  
   
   
       5 . A method of making a disk drive, comprising the step of assembling said disk drive using said actuator of  claim 4 .  
   
   
       6 . Said disk drive as a product of the process of  claim 5 .  
   
   
       7 . A head gimbal assembly as a product of the process, comprising the steps: 
 estimating a thermal pole tip protrusion tendency for said head gimbal assembly; and    selecting said head gimbal assembly whenever said head gimbal assembly does not have said thermal pole tip protrusion tendency;    wherein the step estimated said thermal pole tip protrusion tendency, comprises:    for each member of a track collection, the step of: determining said thermal pole tip protrusion tendency for said head gimbal assembly on said track collection member; and    predicting said thermal pole tip protrusion tendency for said head gimbal assembly based upon, for each of said track collection members, said thermal pole tip protrusion tendency on said track collection member;    wherein said track collection is comprised of an inside diameter track of a disk surface and an outside diameter track of said disk surface.    
   
   
       8 . The head gimbal assembly of  claim 7 , 
 wherein said read-write head provides a magneto-resistance from a disk surface while performing a write operation to said track collection member on said disk surface and provides a voltage while reading said track collection member at a bias current, for each of said track collection members;    wherein said disk surface rotates at a rotational frequency;    wherein the step determining said thermal pole tip protrusion tendency is comprised of at least one member of the collection comprising the steps of:    monitoring a change of said magneto-resistance while said read-write head performs said write operation on said track collection member to determine said thermal pole tip protrusion tendency; and    detecting an amplitude modulation envelope for said voltage at essentially said rotational frequency for said track collection member written to determine said thermal pole tip protrusion tendency.    
   
   
       9 . The head gimbal assembly of  claim 8 , 
 wherein the step monitoring said change is further comprised of:    observing said magneto-resistance while said read-write head performs said write operation on said track collection member to create a sudden MRR change event collection and to create a MRR value;    determining a number of said sudden MRR change event collection members;    determining a change characteristic based upon an amount MRR change divided by said MRR value, for each of said sudden MRR change event collection members; and    determining said thermal pole tip protrusion tendency based upon said number of said sudden MRR change event collection members and based upon said change characteristic for said sudden MRR change event collection members.    
   
   
       10 . The head gimbal assembly of  claim 8 , 
 wherein the step detecting said amplitude modulation envelope is further comprised of the steps of:    said read-write head reading said track collection member at a current bias to create a track voltage table;    processing said track voltage table at essentially said rotational frequency to generate an amplitude modulation envelope for said voltage at essentially said rotational frequency;    calculating a maximum voltage swing for said amplitude modulation envelope;    calculating a deviation from said maximum voltage swing for said amplitude modulation envelope; and    determining said thermal pole tip protrusion tendency for said track collection member based upon said deviation and based upon said maximum voltage swing.    
   
   
       11 . The head gimbal assembly of  claim 7 , 
 wherein said track collection is further comprised of a middle diameter track of said disk surface.    
   
   
       12 . A method of making an actuator, comprising the step of: assembling said actuator using at least one of said head gimbal assemblies of  claim 7 .  
   
   
       13 . Said actuator as a product of the process of  claim 12 .  
   
   
       14 . A method of making a disk drive, comprising the step of assembling said disk drive using said actuator of  claim 13 .  
   
   
       15 . Said disk drive as a product of the process of  claim 14 .  
   
   
       16 . Said head gimbal assembly as a product of the process comprising the steps: 
 determining a thermal pole tip protrusion tendency for said head gimbal assembly containing a read-write head; and    selecting said head gimbal assembly whenever said head gimbal assembly does not have said thermal pole tip protrusion tendency;    wherein the step determining said thermal pole tip protrusion tendency, further comprises:    for each member of a track collection, the step of: determining said thermal pole tip protrusion tendency for said head gimbal assembly on said track collection member; and    predicting said thermal pole tip protrusion for said head gimbal assembly based upon, for each of said track collection members, said thermal pole tip protrusion tendency on said track collection member;    wherein said track collection is comprised of an inside diameter track of a disk surface and an outside diameter track of said disk surface    wherein said read-write head provides a magneto-resistance from a disk surface while performing a write operation to said track collection member on said disk surface and provides a voltage while reading said track collection member at a bias current, for each of said track collection members;    wherein said disk surface rotates at a rotational frequency;    wherein the step determining said thermal pole tip protrusion tendency is comprised of the step of:    detecting an amplitude modulation envelope for said voltage at essentially said rotational frequency for said track written to determine said thermal pole tip protrusion tendency;    wherein the step detecting said amplitude modulation envelope is further comprised of the steps of:    said read-write head reading said track collection member at a current bias to create a track voltage table;    processing said track voltage table at essentially said rotational frequency to generate an amplitude modulation envelope for said voltage at essentially said rotational frequency;    calculating a maximum voltage swing for said amplitude modulation envelope;    calculating a deviation from said maximum voltage swing for said amplitude modulation envelope; and    determining said thermal pole tip protrusion tendency for said track collection member based upon said deviation and based upon said maximum voltage swing.    
   
   
       17 . The method of  claim 16 , 
 wherein said track collection is further comprised of a middle diameter track of said disk surface.    
   
   
       18 . A method of making an actuator, comprising the step of: assembling said actuator using at least one of said head gimbal assemblies of  claim 16 .  
   
   
       19 . Said actuator as a product of the process of  claim 18 .  
   
   
       20 . A method of making a disk drive, comprising the step of assembling said disk drive using said actuator of  claim 19 .  
   
   
       21 . Said disk drive as a product of the process of  claim 20.