Abstract: A method of making a magnetic head according to one embodiment comprises forming a shield layer having first and second recesses in first and second end regions which surround a central region; depositing first and second lead layers in the first and the second recesses; and forming a read sensor in the central region such that a first edge of the read sensor is positioned above an edge of the first lead layer and a second edge of the read sensor is positioned above an edge of the second lead layer.

Abstract: An apparatus for providing an aligned coil for an inductive head structure using a patterned seed layer is disclosed. The present invention uses an aligned process where the base plate imprint is fabricated on an electrically insulating layer and the reversed image is fabricated and etched into the coil insulation material, e.g., hard bake photoresist to alleviate the problems associated with complete ion removal of the seed layer between high aspect ratio coils. The present invention would also not be prone to plating non-uniformities (voids), and would not be subject to seed layer undercutting in a wet etch step process.

Abstract: A a method for fabricating a structure, such as a magnetic head, having two coplanar metallic features of different compositions, both deposited on their own seed layers. The features may be made tall relative to their widths (ie. have a high aspect ratio), and are also very closely spaced. Only a single high-definition, critically aligned photolithographic procedure is used to create the critical structures, avoiding any problem with aligning features produced by multiple procedures. The method is applied to the production of the write structure of a magnetic read/write head, where a portion of the pole structure and the inductive coils are fabricated in the same plane with a close spacing and both having a vertical aspect ratio of more than about 2:1.

Abstract: A magnetic head is made of a shield layer having first and second recesses defined in first and second end regions which surround a central region. Bias and lead layers are formed in the first and the second recesses, and a read sensor is formed in the central region. Advantageously, edges of the bias and lead layers are formed below edges of the read sensor to thereby define a magnetic track width of the read sensor. Also, the sensor profile is substantially flat so that a gap layer over the read sensor can provide for adequate insulation.

Abstract: A method for manufacturing a pole tip structure for a magnetic head is provided. An etch stop layer is initially deposited after which a transfer layer is deposited. Further deposited is at least one masking layer. Reactive ion etching is then performed to define a trench in at least the transfer layer. A pole tip layer is then deposited in the trench to define a pole tip structure flanked at least in part by the transfer layer. A surface of the transfer layer or etch stop layer then remains in co-planar relationship with a surface of the pole tip structure.

Abstract: An embodiment of a magnetic head of the present invention includes a media heating device that is fabricated within the magnetic head structure following the fabrication of the read head element of the magnetic head. The media heating device is preferably fabricated between the first and second magnetic pole layers and close to the ABS surface of the head. The heating device includes electrical leads and an electrically resistive heating element that is preferably comprised of TaSiN, NiCr or NiFe, and in the present invention one or both of the magnetic poles are utilized as an electrical lead of the heating device. The heating device serves to heat the magnetic media immediately prior to the passage of the magnetic media beneath the pole tip, which lowers the localized coercivity of the media and facilitates the writing of data to the media by the write head element of the magnetic head.

Abstract: A method for milling a structure. A single- or multi-layer resist having no undercut is added to a surface of a structure to be milled, the surface to be milled defining a plane. A milling process, such as ion milling, is performed. The milling process includes milling the structure at high incidence and milling the structure at razing incidence. The milling process can be performed only once, or repeated multiple times. High incidence can be defined as about 65 to about 90 degrees from the plane of the surface being milled. Razing incidence can be defined as about 0 to about 30 degrees from the plane of the surface being milled.

Abstract: A method for fabricating a magnetic head includes forming a first pole and a flux shaping layer in spaced relation to the first pole. A nonmagnetic layer is formed adjacent the flux shaping layer and positioned on an air bearing surface (ABS) side of the flux shaping layer. A tapered recess is created in the nonmagnetic layer, the taper of the recess increasing (i.e., becoming deeper) towards the flux forming layer. The recess is filled with a magnetic material. A probe layer is formed such that it is in electrical communication with the magnetic material filling the recess.

Abstract: The present invention is a side-by-side inductive head structure having a considerably reduced separation between the read and write elements of the head structure. The present invention also provides a thin film inductive head design to minimize rework during a fabrication process.

Abstract: A magnetic transducer with a write head with one or more coil layers and a pedestal pole piece on P1 is disclosed. In one embodiment the first and second coils and the P1 pedestal are formed on essentially planarized surfaces. The P1 pedestal defines the zero throat height (ZTH) with a 90 degree apex angle which cuts down flux leakage and improves efficiency. The first and second coils are disposed on opposite sides of the gap layer. The write head preferably has upper and lower back flux closure pieces in contact with the pole pieces to complete the back of the yoke. Various combinations of these features allow heads according to the invention to be made with a very short yoke with resulting improved efficiency. In alternative embodiments the coil below the gap layer may be omitted and/or an additional coil above the gap layer may be added.

Abstract: A magnetic transducer with a bilayer pole piece in which a first layer of material forms the body of the pole piece and a second layer forms the pole tip after milling is disclosed, along with a disk drive using the transducer. The bilayer pole piece is used in a method to improve the determination of the optimum stopping point for the ion milling using the optically observable process of the gap layer and P1 tip layer being milled off of the P1 protection layer forming a gradually disappearing halo. The process of making the head proceeds conventionally through plating of the P1 layer which in applicant's head is the layer which forms the body of P1. The process of the invention deposits a P1 protection layer and then uses a photo lift-off technique to form a void in the P1 protection layer where the gap and the P1 and P2 tips will be formed, i.e., the zero throat region.

Abstract: A method for forming metrology structures on a wafer on which magnetic transducers are being fabricated is disclosed. The metrology structures have a measurable electrical resistance which is an accurate surrogate for a physical dimension of a structure of the magnetic transducer, such as a pole piece tip. The metrology structure is preferably a resistor with pads usable with a four point probe. The resistor is preferably formed by creating a sacrificial pole piece structure over a pad of resistive material. The narrow dimension of the pole tip is then used as a mask to replicate the width of the pole tip in the resistive material through a milling process which removes resistive material outside of the masked area of the resistor pad. Control structures with unmilled pads of resistive material are formed along with the metrology structures to provide the sheet resistance of the pads prior to milling.

Abstract: A magnetic transducer with a bilayer pole piece in which a first layer of material forms the body of the pole piece and a second layer forms the pole tip after milling is disclosed, along with a disk drive using the transducer. The bilayer pole piece is used in a method to improve the determination of the optimum stopping point for the ion milling using the optically observable process of the gap layer and P1 tip layer being milled off of the P1 protection layer forming a gradually disappearing halo. The process of making the head proceeds conventionally through plating of the P1 layer which in applicant's head is the layer which forms the body of P1. The process of the invention deposits a P1 protection layer and then uses a photo lift-off technique to form a void in the P1 protection layer where the gap and the P1 and P2 tips will be formed, i.e., the zero throat region.

Abstract: A method for forming metrology structures on a wafer on which magnetic transducers are being fabricated is disclosed. The metrology structures have a measurable electrical resistance which is an accurate surrogate for a physical dimension of a structure of the magnetic transducer, such as a pole piece tip. The metrology structure is preferably a resistor with pads usable with a four point probe. The resistor is preferably formed by creating a sacrificial pole piece structure over a pad of resistive material. The narrow dimension of the pole tip is then used as a mask to replicate the width of the pole tip in the resistive material through a milling process which removes resistive material outside of the masked area of the resistor pad. Control structures with unmilled pads of resistive material are formed along with the metrology structures to provide the sheet resistance of the pads prior to milling.

Abstract: The present invention is a yoke spin valve MR read head which electrically connects a spin valve MR sensor to spaced apart yoke portions. First and second yoke pieces are electrically connected at a head surface and are insulated from one another at a back gap which is remotely located from the head surface. The first yoke piece has a break which divides it into first and second portions which are spaced from one another. The spin valve MR sensor is located within this break and electrically interconnects the first and second portions of the first yoke piece. First and second leads are connected to the first and second yoke pieces respectively and receive a current from a current source for applying a sense current to the spin valve MR sensor via the first and second yoke pieces. When a magnetic medium is moved adjacent the head surface of the read head the yoke pieces serve as conductors for transmitting sense current to the spin valve MR sensor as well as functioning as a flux guide.

Abstract: An electroplating cell having a cathode assembly which is vertically mounted and which holds a plurality of wafers to be plated, and an anode which is vertically mounted adjacent to the cathode assembly. The anode and cathode are spaced apart and form opposite walls of a channel through which the plating bath flows. The plating bath is introduced through an isostatic chamber which produces, at its output, a substantially equal flow across the width of the channel so that a substantially vertical laminar flow is produced through the channel and the plated deposits are of uniform thickness within a wafer, from wafer to wafer and from batch to batch.