Abstract: As track densities increase, it becomes increasingly important, while writing in a given track, not to inadvertently write data in adjoining tracks. This problem has been overcome by limiting the width of material in the ABS plane to what it is at the write gap. The part of the lower pole that is wider than this is recessed back away from the ABS, thereby greatly reducing its magnetic influence on adjacent tracks. Four different embodiments of write heads that incorporate this notion are described together with a description of a general process for their manufacture.

Abstract: A method for manufacturing a magnetic write head having a write pole with a tapered leading edge and a tapered trailing edge. The method includes forming a non-magnetic bump player over a surface, forming a mask over the non-magnetic bump layer and performing a first ion milling to form a tapered back edge on the non-magnetic bump layer. A magnetic write pole material is then deposited over the surface and over the non-magnetic bump layer. Then a non-magnetic step structure is formed over the magnetic write pole material and an ion milling is performed to form a taper on the upper surface of the write pole. The write pole lateral dimensions can then be defined, and a non-magnetic bump formed over the tapered portion of the upper surface of the write pole. Another ion milling can then be performed to extend the taper of the surface of the write pole.

Abstract: A method of manufacturing the magnetic head includes the steps of: forming the pole-layer-encasing layer; forming an initial nonmagnetic layer in the groove of the pole-layer-encasing layer by physical vapor deposition, the initial nonmagnetic layer being intended to become the nonmagnetic layer later by undergoing etching of a surface thereof; etching the surface of the initial nonmagnetic layer by dry etching so that the initial nonmagnetic layer becomes the nonmagnetic layer; and forming the pole layer in the pole-layer-encasing section formed by the nonmagnetic layer.

Abstract: A method for manufacturing a magnetic write head having a stepped trailing shield. The stepped trailing shield is formed by forming a non-magnetic bump over a write pole prior to electroplating a wrap-around magnetic shield. The method allows the location of the front edge of the bump relative to the back edge of the wrap-around shield to be monitored by measuring the electrical resistance of an electrical lapping guide formed concurrently with these features. This concurrent formation of a lapping guide can be used to define the relative location of other features as well, such as the location of a back edge of a wrap-around shield relative to a flare point of a write pole.

Abstract: A method for manufacturing a magnetic write head having a write pole with a flared step feature that defines a secondary flare point. The method involves depositing a magnetic write pole material on a substrate and then depositing a magnetic material over the write pole material followed by a non-magnetic material. A first mask is formed having a front edge to define the location of the secondary flare point, and one or more material removal processes are used to remove portions of the magnetic layer and non-magnetic layer that are not protected by this first mask. The first mask is replaced by a second mask that is configured to define a write pole, and an ion milling is performed to define the write pole. Shadowing from the magnetic layer and non-magnetic layer form a flared secondary flare point.

Abstract: Embodiments of the invention provide a thin film magnetic head suitable for high density recording having a small erase band ?E and a small fringe magnetic field, and a large recording magnetic field. In one embodiment, a width LW of a lower magnetic pole piece protuberance of a leading side magnetic pole piece, at a face in contact with a write gap layer, is made smaller than a width TW of an upper magnetic pole piece front layer of a trailing side magnetic pole piece, at a face in contact with the write gap layer, and the width of the lower magnetic pole piece protuberance adjacent to the write gap layer is made larger, in a direction from the write gap layer.

Abstract: In one embodiment, a thin-film magnetic head with a write head has a lower core member made of a soft magnetic film, a planar upper core member made of a soft magnetic film, and a coil conductor positioned between the lower and upper core members. The rear end is equipped with a magnetic body, which at least magnetically joins the lower and upper core members. A magnetic pole piece is in contact with the lower core member and positioned toward an air bearing surface, which faces a recording medium. A first nonmagnetic film is provided between a pedestal magnetic pole piece and upper core member. The write head is structured so that the first nonmagnetic film constitutes a write gap. A second nonmagnetic film is provided above or below the first nonmagnetic film. The edge of the second nonmagnetic film is retracted from the air bearing surface. The upper core member's flare point is positioned toward the air bearing surface rather than the edge of the second nonmagnetic film.

Abstract: A magnetic write head and method of manufacture thereof that has a first pole structure having a step notched first pole structure. The step notched structure includes a bottom notched portion that is wider than the second notched portion formed thereover. The upper, or narrower, notched portion has a width that is substantially equal to and self aligned with a second pole structure (P2) formed thereover. The invention may also include first and second wing portions formed in the first pole that are recessed from the ABS and that extend laterally from the first notched portions of the first pole. The formation of the winged portions is assisted by an ion mill resistant bump (alumina bump) formed thereover, which acts as a mask during the ion milling operations that are used to form the first and second notches.

Abstract: A method for manufacturing a thin film magnetic head with a write element, the write element having a first yoke portion and a second yoke portion connected to each other by a back gap portion, a first pole portion and a second pole portion disposed in the medium-facing surface side of the first yoke portion and the second yoke portion respectively, a gap film disposed between the first pole portion and the second pole portion, and a coil surrounding in a spiral form the back gap portion, and the manufacturing method including the steps of forming the coil above the first yoke portion, forming a part which the first pole portion is composed of so that the part extends to cover the upper surface of the coil, forming the gap film on the first pole portion, forming the second yoke portion, which includes the second pole portion, above the gap film, and trimming the first pole portion so as to have a width fitting the second pole portion.

Abstract: A trimmed upper pole piece for a magnetic write head, said pole piece having a tapered profile that is widest at its trailing edge. Such a pole piece is capable of writing narrow tracks with sharply and well defined patterns and minimal overwriting of adjacent tracks. The necessary taper is produced by using NiCr, NiFeCr, Rh or Ru as write gap filling materials which have an etch rate which is substantially equal to the etch rate of the other layers forming the pole piece and are highly corrosion resistant. As a result, the write gap does not protrude to mask the effects of the ion-beam etch used to form the taper.