Method of making a crystallized glass-bonded amorphous metal magnetic film-non-magnetic substrate magnetic head

Claim 1

A method for forming a magnetic head, comprising: (a) providing a first non-magnetic substrate layer having two opposite faces; (b) bonding onto one face of said first non-magnetic substrate layer an amorphous metallic magnetic film layer having an uncovered face; (c) providing a second non-magnetic substrate layer having two opposite faces; (d) bonding onto one face of said second non-magnetic substrate layer a layer of crystallizable glass in an amorphous state, said layer of crytallizable glass having a thickness of 1 to 10 μm and an uncovered face; said amorphous metallic magnetic film layer having an elevated crystallizing temperature; said crystallizable glass layer having an elevated softening temperature which is lower than said crystallizing temperature of said amorphous metallic magnetic film layer; said crystallizable glass layer being made of a glass which, when in a crystallized state, has a melting point which is higher by about 100° C. than said softening temperature; (e) facially confrontig said uncovered face of said amorphous metallic magnetic film layer with said uncovered face of said crystallizable glass layer, thereby covering said uncovered faces and providing a sandwich arrangement having at least four layers; (f) baking said sandwich arrangement at a temperature below the crystallizing temperature of said amorphous metallic magnetic film layer, but sufficiently elevated as to cause crystallization of said crystallizable glass layer, thereby bonding said amorphous metallic magnetic film layer to said second non-magnetic substrate layer with a layer of crystallized glass; (g) dividing said sandwich arrangement into at least two core blocks each comprising said at least four layers, disposed in a respective layer-to-layer connected sandwich arrangement, each layer having two opposite faces and an outer peripheral edge, a length and width extending generally parallel to said faces thereof, and a thickness extending generally perpendicular to said faces thereof; one of said two core blocks being provided in an outer edge portion thereof with a coil window; (h) providing said one core block edgewise in two portions thereof located oppositely perimetrically adjacent said coil window with a layer of gap spacer film; (i) providing the other of said two core blocks edgewise in at least one portion thereof spatially corresponding to said two portions on said one core block with a layer of bonding glass film; (j) placing said two core blocks in edge to edge confrontation with said layer of gap spacer film confronting said layer of bonding glass film; (k) heating said two core blocks to a temperature not substantially higher than the baking temperature used in step (f), thereby bonding said two core blocks together at least partially by means of said bonding glass film into a composite block, with said gap spacer film providing a gap between respective edge portions of said amorphous metallic magnetic film layer of said two core blocks; and (l) profiling an edge of said composite block, including an intersection of said gap therewith to provide a tape running surface on which are exposed a series of at least four connected layers including a first non-magnetic substrate layer, an amorphous metallic magnetic film layer, a crystallized glass layer and a second non-magnetic substrate layer.

Claim 2

A method for forming a magnetic head, comprising: (a) providing a first non-magnetic substrate layer having two opposite faces; (b) bonding onto one face of said first non-magnetic substrate layer an amorphous metallic magnetic film layer having an uncovered face; (c) providing a second non-magnetic substrate layer having two opposite faces; (d) bonding onto one face of said second non-magnetic substrate layer a layer of crystallizable glass in an amorphous state, said layer of crytallizable glass having a thickness of 1 to 10 μm and an uncovered face; said amorphous metallic magnetic film layer having an elevated crystallizing temperature; said crystallizable glass layer having an elevated softening temperature which is lower than said crystallizing temperature of said amorphous metallic magnetic film layer; said crystallizable glass layer being made of a glass which, when in a crystallized state, has a melting point which is higher by about 100° C. than said softening temperature; (e) facially confrontig said uncovered face of said amorphous metallic magnetic film layer with said uncovered face of said crystallizable glass layer, thereby covering said uncovered faces and providing a sandwich arrangement having at least four layers; (f) baking said sandwich arrangement at a temperature below the crystallizing temperature of said amorphous metallic magnetic film layer, but sufficiently elevated as to cause crystallization of said crystallizable glass layer, thereby bonding said amorphous metallic magnetic film layer to said second non-magnetic substrate layer with a layer of crystallized glass; (g) dividing said sandwich arrangement into at least two core blocks each comprising said at least four layers, disposed in a respective layer-to-layer connected sandwich arrangement, each layer having two opposite faces and an outer peripheral edge, a length and width extending generally parallel to said faces thereof, and a thickness extending generally perpendicular to said faces thereof; one of said two core blocks being provided in an outer edge portion thereof with a coil window; (h) providing said one core block edgewise in two portions thereof located oppositely perimetrically adjacent said coil window with a layer of gap spacer film; (i) providing the other of said two core blocks edgewise in at least one portion thereof spatially corresponding to said two portions on said one core block with a layer of bonding glass film; (j) placing said two core blocks in edge to edge confrontation with said layer of gap spacer film confronting said layer of bonding glass film; (k) heating said two core blocks to a temperature not substantially higher than the baking temperature used in step (f), thereby bonding said two core blocks together at least partially by means of said bonding glass film into a composite block, with said gap spacer film providing a gap between respective edge portions of said amorphous metallic magnetic film layer of said two core blocks; and (l) profiling an edge of said composite block, including an intersection of said gap therewith to provide a tape running surface on which are exposed a series of at least four connected layers including a first non-magnetic substrate layer, an amorphous metallic magnetic film layer, a crystallized glass layer and a second non-magnetic substrate layer.