Patent ID: 7975366
Filing Date: 2011-07-12
Classification: G11B,H01F,Y10T

Abstract:
1. A process to form a mold for use in the manufacture of a magnetic component that includes a write pole, having an ABS, a neck height, and a yoke that is connected to said write pole at a flare point, comprising: providing a liftoff mask on an alumina substrate and then depositing thereon a first layer of tantalum whereby, after said liftoff mask has lifted off, said first layer of tantalum covers an area within which said yoke is to be formed and has an edge that slopes towards said substrate at an angle of about 45 degrees; depositing a layer of alumina on all exposed surfaces and then planarizing until said first tantalum layer is just exposed; depositing a second layer of tantalum; depositing and patterning a layer of photoresist to form a mask that defines areas for said write pole and yoke with said flare point being directly over said edge that slopes towards said substrate; and then, by means of reactive ion etching (RIE), etching all exposed surfaces under conditions such that a cavity is formed in the alumina and tantalum layers, said cavity having a floor and a top as well as sidewalls that slope at an angle of between about 7 and 12 degrees in the deposited alumina layer and at an angle of up to about 4 degrees in the second tantalum layer, whereby said neck height is the same at said cavity floor as at said cavity top.