Patent ID: 8287748
Filing Date: 2012-10-16
Classification: G11B

Abstract:
1. A method of manufacturing a magnetic head for perpendicular magnetic recording, the magnetic head comprising: a medium facing surface that faces a recording medium; a coil that produces a magnetic field corresponding to data to be recorded on the recording medium; a pole layer that allows a magnetic flux corresponding to the magnetic field produced by the coil to pass, and produces a recording magnetic field for recording the data on the recording medium by means of a perpendicular magnetic recording system; a bottom forming layer made of a nonmagnetic material; an accommodation layer made of a nonmagnetic material, disposed on the bottom forming layer, and having a groove that opens in a top surface of the accommodation layer and accommodates the pole layer; and a substrate on which the bottom forming layer, the accommodation layer, the pole layer and the coil are stacked, the substrate having a top surface, wherein: the pole layer includes: a track width defining portion having an end face that is located in the medium facing surface and an end that is opposite to the end face, the end face defining a track width; and a wide portion that is connected to the end of the track width defining portion and has a width greater than that of the track width defining portion; the end face of the track width defining portion located in the medium facing surface has a width that decreases with decreasing distance from the top surface of the substrate; the groove includes: a first portion for accommodating at least part of the track width defining portion of the pole layer; and a second portion for accommodating at least part of the wide portion of the pole layer, the second portion being farther from the medium facing surface than the first portion; the first portion has a width that decreases with decreasing distance from the top surface of the substrate; and the second portion penetrates the accommodation layer, the method comprising the steps of: forming the bottom forming layer; forming a nonmagnetic layer on the bottom forming layer, the nonmagnetic layer being intended to undergo formation of the groove therein later to thereby become the accommodation layer; forming a groove defining layer on the nonmagnetic layer, the groove defining layer having a penetrating opening that has a shape corresponding to a plane geometry of the groove to be formed later; forming the groove in the nonmagnetic layer so that the nonmagnetic layer becomes the accommodation layer; forming the pole layer such that the pole layer is accommodated in the groove of the accommodation layer; and forming the coil, wherein the step of forming the groove in the nonmagnetic layer includes: the step of forming a mask that covers an area of the nonmagnetic layer where to form the first portion of the groove; the first etching step of etching the nonmagnetic layer by reactive ion etching, with the mask and the groove defining layer used as an etching mask, so that the second portion of the groove is formed in the nonmagnetic layer; the step of removing the mask; and the second etching step of taper-etching the nonmagnetic layer by reactive ion etching, with the groove defining layer used as an etching mask, so that the first portion of the groove is formed in the nonmagnetic layer and the groove is thereby completed, and wherein: each of the bottom forming layer and the groove defining layer is lower in etching rate in the first and second etching steps than the nonmagnetic layer; the second etching step uses an etching gas that contains a main component contributing to the etching of the nonmagnetic layer and a gas serving to form a sidewall-protecting film, and the first etching step uses an etching gas that contains the main component and does not contain the gas serving to form the sidewall-protecting film.