Advance pole trim writer with moment P1 and low apex angle

Details Advance pole trim writer with moment P1 and low apex angle Advance pole trim writer with moment P1 and low apex angle

1999-08-31

2001-11-13

Tupper, Robert S. (Department: 2652)

Dynamic magnetic information storage or retrieval

Head

Core

Reexamination Certificate

active

06317290

ABSTRACT:

BACKGROUND OF THE INVENTION
This invention relates generally to magnetic disk data storage systems, and more particularly to magnetic write transducers and methods of making same.
Magnetic disk drives are used to store and retrieve data for digital electronic apparatuses such as computers. In
FIGS. 1A and 1B
, a magnetic disk data storage systems
10
of the prior art includes a sealed enclosure
12
, a disk drive motor
14
, a magnetic disk
16
, supported for rotation by a drive spindle S
1
of motor
14
, an actuator
18
and an arm
20
attached to an actuator spindle S
2
of actuator
18
. A suspension
22
is coupled at one end to the arm
20
, and at its other end to a read/write head or transducer
24
. The transducer
24
(which will be described in greater detail with reference to
FIG. 2A
) typically includes an inductive write element with a sensor read element. As the motor
14
rotates the magnetic disk
16
, as indicated by the arrow R, an air bearing is formed under the transducer
24
causing it to lift slightly off of the surface of the magnetic disk
16
, or, as it is termed in the art, to “fly” above the magnetic disk
16
. Alternatively, some transducers, known as “contact heads,” ride on the disk surface. Various magnetic “tracks” of information can be written to and/or read from the magnetic disk
16
as the actuator
18
causes the transducer
24
to pivot in a short arc as indicated by the arrows P. The design and manufacture of magnetic disk data storage systems is well known to those skilled in the art.
FIG. 2A
depicts a magnetic read/write head
24
including a substrate
25
above which a read element
26
and a write element
28
are disposed. Edges of the read element
26
and write element
28
also define an air bearing surface ABS, in a plane
29
, which can be aligned to face the surface of the magnetic disk
16
(see FIGS.
1
A and
1
B). The read element
26
includes a first shield
30
, an intermediate layer
32
, which functions as a second shield, and a read sensor
34
that is located within a dielectric medium
35
between the first shield
30
and the second shield
32
. The most common type of read sensor
34
used in the read/write head
24
is the magnetoresistive (AMR or GMR) sensor which is used to detect magnetic field signals from a magnetic medium through changing resistance in the read sensor.
The write element
28
is typically an inductive write element which includes the intermediate layer
32
, which functions as a first pole, and a second pole
38
disposed above the first pole
32
. The first pole
32
and the second pole
38
are attached to each other by a backgap portion
40
, with these three elements collectively forming a yoke
41
. The combination of a first pole tip portion
43
and a second pole tip portion
45
near the ABS are sometimes referred to as the yoke tip portion
46
. A write gap
36
is formed between the first and second poles
32
,
38
in the yoke tip portion
46
. The write gap
36
is filled with a non-magnetic electrically insulating material that forms a write gap material layer
37
. This non-magnetic material can be either integral with (as is shown here) or separate from a first insulation layer
47
that lies below the second yoke
38
and extends from the yoke tip portion
46
to the backgap portion
40
.
Also included in write element
28
is a conductive coil
48
, formed of multiple winds
49
which each have a wind height Hw. The coil
48
can be characterized by a dimension sometimes referred to as the wind pitch P, which is the distance from one coil wind front edge to the next coil wind front edge, as shown in FIG.
2
A. As is shown, the wind pitch P is defined by the sum of the wind thickness Tw and the separation between adjacent winds Sw. The conductive coil
48
is positioned within a coil insulation layer
50
that lies above the first insulation layer
47
. The first insulation layer
47
thereby electrically insulates the coil layer from the first pole
32
, while the coil insulation layer
50
electrically insulates the winds
49
from each other and from the second pole
38
.
The configuration of the conductive coil
48
can be better understood with reference to a plan view of the read/write head
24
shown in
FIG. 2B
taken along line
2
B—
2
B of FIG.
2
A. Because the conductive coil extends beyond the first and second poles, insulation may be needed beneath, as well as above, the conductive coil to electrically insulate the conductive coil from other structures. For example, as shown in
FIG. 3
, a view taken along line
3
—
3
of
FIG. 2A
, a buildup insulation layer
52
can be formed adjacent the first pole, and under the conductive coil layer
48
. As is well known to those skilled in the art, these elements operate to magnetically write data on a magnetic medium such as a magnetic disk
16
(see FIGS.
1
A and
1
B).
More specifically, an inductive write head such as that shown in
FIGS. 2A-3
operates by passing a writing current through the conductive coil layer
48
. Because of the magnetic properties of the yoke
41
, a magnetic flux is induced in the first and second poles
32
,
38
by write currents passed through the coil layer
48
. The write gap
36
allows the magnetic flux to fringe out from the yoke
41
(thus forming a fringing gap field) and to cross a magnetic recording medium that is placed near the ABS. A critical parameter of a magnetic write element is a trackwidth of the write element, which defines track density. For example, a narrower trackwidth can result in a higher magnetic recording density. The trackwidth is defined by geometries in the yoke tip portion
46
(see
FIG. 2A
) at the ABS. These geometries can be better understood with reference to FIG.
3
. As can be seen from this view, the first and second poles
32
,
38
can have different widths W
1
, W
2
respectively in the yoke tip portion
46
(see FIG.
2
A). In the shown configuration, the trackwidth of the write element
28
is defined by the width W
2
of the second pole
38
. The gap field of the write element can be affected by the throat height TH, which is measured from the ABS to the zero throat ZT, as shown in FIG.
2
A. The strength of the gap field strongly affects the over writing performance of a recording head. Thus, accurate definition of the trackwidth and throat height is critical during the fabrication of the write element.
However, the control of trackwidth, and throat height can be limited by typical fabrication processes, an example of which is shown in the process diagram of FIG.
4
. The method
54
includes providing a first pole with first and second edges in operation
56
. This operation can include, for example, forming a plating dam, plating, and then removing the dam. In operation
58
, a write gap material layer is formed over the first pole. In particular, the write gap material layer is formed over an upper surface and the first and second edges of the first pole. Also, in operation
58
, a via is formed through the write gap material layer to the first pole in the backgap portion
40
(see FIG.
2
A). In the instance herein described, the write gap material layer extends above the first pole in the area between the yoke tip portion and the backgap portion, although in other cases the write gap material layer may not be above this area A buildup insulation layer is also formed in operation
60
, adjacent the first and second edges, with the write gap material layer between the first pole and the buildup insulation layer. The buildup insulation layer is typically formed by depositing (e.g., spinning) and patterning photoresistive material and then hard baking the remaining photoresistive material. Such processes often result in the height of the buildup insulation layer being non-uniform and different than the height of the write gap material layer, as is illustrated in
FIGS. 2A and 3
.
The method
54
also includes forming a first coil layer above the write gap material layer and the buildup insulation layer in operation
62
. This can i

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