Patent ID: 6069015
Filing Date: 2000-05-30
Classification: G11B,Y10T

Abstract:
A method of fabricating a thin film magnetic head comprising:depositing a first seed layer on a substrate having a substantially planar surface;plating a lower magnetic layer on the first seed layer, the lower magnetic layer having first and second opposed ends, the first seed layer being the seed for plating the lower magnetic layer;plating a plurality of layers of magnetic material at the first end of the lower magnetic layer to build-up a first side pole stacked so that the plurality of layers form a first column in a direction perpendicular to the substrate surface and having a first top surface, this plating step using the first seed layer as a common seed for the build-up of the plurality of layers of the first side pole;plating a plurality of layers of magnetic material at the second end of the lower magnetic layer to build-up a second side pole stacked so that the plurality of layers form a second column in a direction perpendicular to the substrate surface and having a second top surface, this plating step using the first seed layer as a common seed for the build-up of the plurality of layers of the second side pole;forming a coil structure about one of the first and second side poles;forming an insulative body about the first and second side poles and the coil structure;forming an insulative pedestal in a generally horizontal plane overlying the insulative body and extending laterally to fully enclose the first and second side pole top surfaces;forming a first aperture in the insulative pedestal overlying the first side pole and a second aperture in the insulative pedestal overlying the second side pole;plating a layer of magnetic material overlying the first side pole extending through the first aperture in the insulative pedestal and plating a layer of magnetic material overlying the second side pole extending through the second aperture in the insulative pedestal;depositing a second seed layer including first and second portions on the insulative pedestal leaving undeposited the layers of magnetic material of the first and second side poles extending through the first and second apertures;depositing a first upper magnetic pole element at the first top surface, integrally, directly and magnetically coupled to the first side pole, and on the first portion of the second seed layer, the first upper magnetic pole element including a first gap end extending toward the second top surface;forming a gap region of nonmagnetic material at the first gap end of the first upper magnetic pole element;depositing a second upper magnetic pole element at the second top surface, integrally, directly and magnetically coupled to the second side pole, and on the second portion of the second seed layer, the second upper magnetic pole element including a second gap end situated adjacent the gap region;removing the second seed layer except for portions of said second seed layer below the first and second upper magnetic pole elements and the gap region; andforming a diamond-like carbon (DLC) frame above the insulative pedestal and surrounding the first and second upper magnetic pole elements and gap region to provide structural integrity to the head and wear protection therefor.