Patent ID: 7355813
Filing Date: 2008-04-08
Classification: G11B,Y10S,Y10T

Abstract:
1. A magnetic write pole comprising: a projection comprising a rectangular prism extending outwardly from a substrate, said projection comprising a laterally unsupported portion and a laterally supported portion, said projection having a width in a thinnest dimension measured parallel to a surface of the substrate of not more than about 0.3 micrometers and a height measured perpendicular to said substrate surface of not less than about 5 times the width, said laterally supported portion of said projection in direct contact with a filler and a replication layer formed on the substrate, fabrication of said projection comprising: forming an overlying structure on the substrate, the overlying structure having an edge thereon, wherein forming the overlying structure includes: 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, the continuous layer having a free surface with a side of the replication layer exposed at the free surface; selectively removing at least a portion of the replication layer from the free surface inwardly toward the substrate, to form a defined cavity; and depositing a projection material into the defined cavity to form the laterally supported portion of said projection, the laterally supported portion of said projection in direct contact with the filler, replication layer, and substrate wherein the filler comprises a hard-baked resist material, and the replication layer comprises a replication material that is not attacked by a process used to selectively remove laterally adjacent layers in subsequent process steps, the replication material selectively etched by ion etching in a fluorine-containing atmosphere and not attacked by ion etching in an oxygen or carbon monoxide atmosphere.