Abstract: Unlike conventional dental ceramic powder made by grinding, dental ceramic nanocrystals are formed by vaporization into individual particles. Tetragonal zirconia particles thus formed are not broken into pieces, and so do not transform to weaker monoclinic zirconia and weaker sintered products. The particles created by this approach can be much smaller, and dental prostheses sintered from this powder can be stronger and more realistic. For instance, the smaller size of sintered tetragonal zirconia crystals increases optical translucence by reducing scattering from birefringence, and the small average particle size and tight distribution of sizes and shapes can essentially eliminate pores in a sintered product. Cylindrical and spherical particles can be manufactured by this approach, whereas prior art dental ceramic particles were generally neither.

Abstract: Unlike conventional dental ceramic powder made by grinding, dental ceramic nanocrystals are formed by vaporization into individual particles. Tetragonal zirconia particles thus formed are not broken into pieces, and so do not transform to weaker monoclinic zirconia and weaker sintered products. The particles created by this approach can be much smaller, and dental prostheses sintered from this powder can be stronger and more realistic. For instance, the smaller size of sintered tetragonal zirconia crystals increases optical translucence by reducing scattering from birefringence, and the small average particle size and tight distribution of sizes and shapes can essentially eliminate pores in a sintered product. Cylindrical and spherical particles can be manufactured by this approach, whereas prior art dental ceramic particles were generally neither.

Abstract: A method and system for forming a microscopic transducer are described. The method and system include forming a plurality of adjoining sensor layers. The sensor layers include a first magnetically soft layer, a nonmagnetic layer on the first magnetically soft layer, and a second magnetically soft layer on the nonmagnetic layer. The method and system also include forming a sidewall over the second magnetically soft layer. The sidewall formation includes forming a base having a surface oriented substantially perpendicular to the sensor layers and depositing an electrically conductive material on the surface. The method and system also include removing a portion of the sensor layers not covered by the sidewall.

Abstract: Methods are provided for forming current perpendicular to the plane thin film read heads. In one embodiment, the method comprises the steps of forming a lower sensor lead, forming a lower sensor lead cladding of a low sputter yield material on the lower sensor lead, forming a sensor element on the lower sensor lead cladding, and forming an upper sensor lead coupled to the sensor element. The low sputter yield material helps to reduce redeposition of the lower sensor lead material onto side walls of the sensor element as the sensor element is being formed.

Abstract: A trailing pole-tip for an electromagnetic transducer is formed as a layer oriented substantially perpendicular to other layers of the transducer, allowing the pole-tip to be made much thinner than conventional pole-tips. The novel pole-tip is formed on an edge or sidewall of a base layer instead of being formed on top of an existing layer. Potential errors in pole-tip thickness are much less than standard error tolerances for conventional pole-tip thickness. Having a greatly reduced pole-tip width significantly reduces the track width so that many more tracks can fit on a media surface, providing a large increase in areal density.

Abstract: A coating for a biomedical device is disclosed, including a metal layer and/or a ceramic layer, such as a layer of titanium (Ti) and a layer of titanium-nitride (TiN). The coating can form a coping for a crown for a tooth, the crown including a porcelain layer bonded to the titanium-nitride (TiN) layer. Methods for making and using a biomedical device are also disclosed, including vapor deposition of metal and/or ceramic layers, such as titanium (Ti) and titanium-nitride (TiN) layers. In one embodiment, the method includes forming a titanium (Ti) vapor that solidifies to form a titanium (Ti) layer; forming a titanium-nitride (TiN) vapor that coats the titanium (Ti) layer with a titanium-nitride (TiN) layer; and forming a porcelain layer on the titanium-nitride (TiN) layer. The porcelain can be sintered to form a dental crown or other device.

Abstract: The present invention provides an improved current perpendicular to the plane thin film read head device and method of fabrication. With the present invention, the lower lead is formed to inhibit accumulation of redeposited lead material on CPP sensor element side walls during CPP sensor formation. In the preferred embodiment, the upper portion of the lower lead, which normally is etched during sensor element formation, is formed of a low sputter yield material to reduce redeposition flux to the sensor side walls. It is also preferred to form the upper portion of a material that also has a low value for the ratio of its sputter yield at the lead milling angle-to-its sputter yield at the side wall milling angle to inhibit redeposition accumulation on the side wall. It is preferred to clad conventional lead material with a low sputter yield ratio, low resistivity material, to inhibit side wall redeposition accumulation while also providing a low resistance lower lead.

Abstract: Methods for reducing feature sizes of devices such as electromagnetic sensors are disclosed. A track width of a MR sensor is defined by a mask having an upper layer with a reduced width and a lower layer with a further reduced width. Instead of or in addition to being supported by the lower layer in the area defining the sensor, the upper layer is supported by the lower layer in areas that do not define the sensor width. In some embodiments the upper layer forms a bridge mask, supported at its ends by the lower layer, and the lower layer is completely removed over an area that will become a sensor. Also disclosed is a mask having more than two layers, with a bottom layer completely removed over the sensor area, and a middle layer undercut relative to a top layer.

Abstract: The present invention provides a thin film read head having a lower shield pedestal with an adjacent lower extra gap layer. The pedestal may be formed from a lower shield layer with the lower extra gap layer being inset within the lower shield layer so that the top surfaces of the lower extra gap layer and the pedestal are generally planar. This allows for deposition of generally planar lower gap and sensor layers. A sensor element may be defined on the generally planar surface using a bilayer resist structure. The generally planar surface of the sensor layer inhibits resist pooling which could otherwise degrade resist structure and sensor element formation. In a typical embodiment, the read head of the present invention may have a spin valve type sensor element with leads electrically coupled to the sensor element, an upper gap layer extending between the sensor element and the upper shield layer, and an upper extra gap layer disposed between at least a portion of the leads and the upper shield layer.

Abstract: A coating for a biomedical device is disclosed, including a metal layer and/or a ceramic layer, such as a layer of titanium (Ti) and a layer of titanium-nitride (TiN). The coating can form a coping for a crown for a tooth, the crown including a porcelain layer bonded to the titanium-nitride (TiN) layer. Methods for making and using a biomedical device are also disclosed, including vapor deposition of metal and/or ceramic layers, such as titanium (Ti) and titanium-nitride (TiN) layers. In one embodiment, the method includes forming a titanium (Ti) vapor that solidifies to form a titanium (Ti) layer; forming a titanium-nitride (TiN) vapor that coats the titanium (Ti) layer with a titanium-nitride (TiN) layer; and forming a porcelain layer on the titanium-nitride (TiN) layer. The porcelain can be sintered to form a dental crown or other device.

Abstract: The present invention provides an improved bias magnet-to-magnetoresistive element interface and method of fabrication. In a preferred embodiment, the wall/walls of an MR element opposing a bias layer are formed by over etching to provide vertical side walls without taper. In the preferred embodiment, a protective element is formed over the MR element to protect it during etch processes. In some embodiments, a filler layer is deposited prior to bias layer formation. In CIP embodiments, any portion of the filler layer forming on vertical side walls of the MR element is etched to provide an exposed side wall surface for contiguous bias layer formation. In CPP embodiments, the filler layer forms on a vertical back wall and electrically insulates the MR element from the bias layer.

Abstract: An electrically conductive sidewall for an electromagnetic transducer having a magnetoresistive sensor is formed as a layer oriented substantially perpendicular to other layers of the sensor, and is used as a mask for defining the width of the sensor. This allows the sensor to be made much thinner than conventional sensors, providing higher resolution in a track width direction. The sidewall can be nonmagnetic, serving as a spacer between the magnetic sensor layers and an adjacent magnetic shield without the need for a protective cap to guard against damage from polishing and wet etching. Alternatively, the sidewall can be magnetic, serving as an extension of the shield. In either case, the sidewall reduces the effective length of the sensor for linear resolution, sharpening the focus of the sensor and increasing linear density. Also reduced is the tolerance for error in sensor width and length.

Abstract: A magnetoresistive device includes a metal layer, formed over a substrate, in which a groove is formed. A magnetoresistive element is formed in the groove, forming two magnetoresistive element portions that are separated by a conductive element. A sense current applied to the metal layer flows through the two magnetoresistive element portions with a predominant current-perpendicular-to-plane component. The method includes techniques that are less complex and less expensive than submicron photolithography to form the above described magnetoresistive device with submicron geometries.

Abstract: A magnetoresistive (MR) transducer has at least one insulative layer made of tetrahedral amorphous carbon (ta-C). The ta-C layer is formed by filtered cathodic arc deposition, has an essentially zero concentration of hydrogen and can serve as a read gap for the transducer. The hydrogen-free t-aC read gap has high thermal conductivity, keeping an adjoining MR sensor from overheating during operation. This extends sensor lifetimes and/or improves sensor performance. The read gap also has low defects and porosity, preventing unwanted electrical conduction or shorting between a sensor and a shield. The high hardness of the read gap resists plasma and chemical etching processes such as ion milling that are used to form the sensor. The increased hardness and reduced defects and porosity allow the read gaps to be made thinner without risking electrical shorting. Other hydrogen-free t-aC layers are employed for other sensor elements where electrical insulation and reduced thickness are important.

Abstract: The present invention provides an improved bias magnet-to-magnetoresistive element interface and method of fabrication. In a preferred embodiment, the wall/walls of an MR element opposing a bias layer are formed by over etching to provide vertical side walls without taper. In the preferred embodiment, a protective element is formed over the MR element to protect it during etch processes. In some embodiments, a filler layer is deposited prior to bias layer formation. In CIP embodiments, any portion of the filler layer forming on vertical side walls of the MR element is etched to provide an exposed side wall surface for contiguous bias layer formation. In CPP embodiments, the filler layer forms on a vertical back wall and electrically insulates the MR element from the bias layer.

Abstract: The present invention provides an exchange break to define the track width of a read head by selectively isolating an exchange coupling layer from an underlying ferromagnetic layer. In the preferred embodiment, the exchange break is provided over a portion of the free layer of a spin valve device so that it inhibits exchange coupling between an overlying portion of the exchange coupling layer and the underlying free layer to define an active region. It is preferred to form the exchange break of an electrically insulating material, to inhibit current shunting through the exchange break, and of a material that easily etches, to minimize inadvertent etching of the underlying free layer and to ensure complete removal of exchange break material when forming the exchange break from an exchange break layer. A reentrant profile photoresist structure may be used to define the exchange break and to define the exchange coupling layer.

Abstract: The present invention provides an improved current perpendicular to the plane thin film read head device and method of fabrication. With the present invention, the lower lead is formed to inhibit accumulation of redeposited lead material on CPP sensor element side walls during CPP sensor formation. In the preferred embodiment, the upper portion of the lower lead, which normally is etched during sensor element formation, is formed of a low sputter yield material to reduce redeposition flux to the sensor side walls. It is also preferred to form the upper portion of a material that also has a low value for the ratio of its sputter yield at the lead milling angle-to-its sputter yield at the side wall milling angle to inhibit redeposition accumulation on the side wall. It is preferred to clad conventional lead material with a low sputter yield ratio, low resistivity material, to inhibit side wall redeposition accumulation while also providing a low resistance lower lead.

Abstract: The present invention provides an improved bias magnet-to-magnetoresistive element interface and method of fabrication. In a preferred embodiment, the wall/walls of an MR element opposing a bias layer are formed by over etching to provide vertical side walls without taper. In the preferred embodiment, a protective element is formed over the MR element to protect it during etch processes. In some embodiments, a filler layer is deposited prior to bias layer formation. In CIP embodiments, any portion of the filler layer forming on vertical side walls of the MR element is etched to provide an exposed side wall surface for contiguous bias layer formation. In CPP embodiments, the filler layer forms on a vertical back wall and electrically insulates the MR element from the bias layer.

Abstract: In at least one embodiment, the method of the present invention is embodied in a method for fabricating a magnetoresistive head structure which includes obtaining a lead and magnetic bias layer, applying a photoresist layer over the lead and magnetic bias layer and about a desired position of a sensor such that the desired position of the sensor is substantially free of the photoresist layer, etching the lead and magnetic bias material substantially at the desired position of the sensor, depositing a sensor at the desired position of the sensor; and removing the photoresist. Obtaining the lead and magnetic bias layers can be done by depositing them.

Abstract: The present invention provides a thin film write head having an upper and lower pole structures and conductor turns forming a winding for generating magnetic flux. The conductor is formed with a non-planar top surface. The winding of the present invention may be formed of lower and upper turns. The upper turns may be formed with a non-planar top surface, a non-planar bottom surface, or both. It is preferred that the bottom surface of the upper conductor turns be coherent with the non-planar top surface of the lower conductor turns. The non-planar top surface may be formed by removing corners formed during deposition between a generally planar top surface and abutting side walls. The corners may be removed by ion milling to form the non-planar top surface. The conductor may be copper with the non-planar top surface having sloping facets. The thin film write head of the present invention may be utilized to provide an improved data storage and retrieval apparatus.