Patent ID: 6328859
Filing Date: 2001-12-11
Classification: G11B

Abstract:
A method of making a write head, the write head having an air bearing surface (ABS), a pole tip region commencing at the ABS, a back gap region and a yoke region between the pole tip region and the back gap region, a final second pole tip in the pole tip region that has a final height at the ABS and a final track width at the ABS, the final track width being substantially perpendicular to a direction of media movement, the method comprising:forming a first pole piece layer of ferromagnetic material in the pole tip region, yoke region and back gap region;forming a non-magnetic write gap layer on the first pole piece layer at least in the pole tip region;forming a mask on the write gap layer that has an opening with first and second side walls, the side walls being located in the pole tip region and being separated by a width at the ABS that is substantially perpendicular to said direction of media movement;said width being wider than said final track width;forming ferromagnetic material on said write gap within said opening to form a preliminary second pole tip, the preliminary second pole tip having preliminary first and second side walls that are formed by the first and second side walls of the mask, the preliminary first and second side walls being located in the pole tip region and having a preliminary width and said final height at the ABS, the preliminary width being greater than said final track width;forming a non-magnetic electrically conductive sacrificial layer on said preliminary second pole tip within said opening;removing the mask; andion milling said preliminary first and second side walls at a predetermined angle relative to surfaces of the preliminary first and second side walls;said predetermined angle being sufficient for the ion milling to reduce said preliminary width to said final track width without completely removing said sacrificial layer;said ion milling having a duration, said duration being determined by:determining a difference between a plurality of preliminary widths and a final width; and,dividing the difference by a milling rate of the material of the preliminary second pole tip.