Method of fabricating a narrow projection such as a write...

Metal working – Method of mechanical manufacture – Electrical device making

Reexamination Certificate

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C029S603120, C029S603150, C029S603180, C029SDIG001, C216S011000, C216S022000, C216S047000, C204S192100, C204S192110, C430S315000, C430S320000, C360S122000, C360S125020

Reexamination Certificate

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06859998

ABSTRACT:
An article is formed as a substrate having a projection extending outwardly therefrom. The article may be a magnetic recording head and the projection a write pole. The projection has a width in a thinnest dimension measured parallel to a substrate surface of no more than about 0.3 micrometers and a height measured perpendicular to the substrate of not less than about 5 times the width. The article is fabricated by forming an overlying structure on the substrate with an edge thereon, depositing a replication layer lying on the edge, depositing a filler onto the edge and the substrate, so that the filler, the replication layer, and the overlying structure in combination comprise a continuous layer on the substrate, selectively removing at least a portion of the replication layer from a free surface of the continuous layer inwardly toward the substrate, to form a defined cavity, and depositing a projection material into the defined cavity to form the projection.

REFERENCES:
patent: 5595941 (1997-01-01), Okamoto et al.
patent: 5618383 (1997-04-01), Randall
patent: 5667632 (1997-09-01), Burton et al.
patent: 5688723 (1997-11-01), Okamoto et al.
patent: 6043960 (2000-03-01), Chang et al.
patent: 6054023 (2000-04-01), Chang et al.
patent: 20010000917 (2001-05-01), Arndt et al.
patent: 60-217603 (1985-10-01), None
patent: 61-174616 (1996-08-01), None

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