Magnetic sensing element having specular layer

A specular layer and a nonmagnetic layer are provided on a central portion of a free magnetic layer, and ferromagnetic layers and second antiferromagnetic layers are provided on both end portions of the free magnetic layer. In the present invention, the total thickness of the specular layer and the nonmagnetic layer can be decreased, and thus ion milling for removing the layers from both end portions of the free magnetic layer can be performed with low energy. Therefore, both end portions of the free magnetic layer are less damaged by ion milling, and ferromagnetic coupling produced between both end portions of the free magnetic layer and the ferromagnetic layers can be increased, thereby permitting appropriate control of magnetization of the free magnetic layer.

This application claims the benefit of priority to Japanese Patent Application 2001-305143, filed on Oct. 1, 2001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a magnetic sensing element used for a hard disk device, a magnetic sensor, etc., and particularly to a magnetic sensing element having a specular layer with excellent reproducing characteristics, and permitting proper control of the magnetization of a free magnetic layer even with a narrower track, and a method of manufacturing the magnetic sensing element.

2. Description of the Related Art

In order to appropriately comply with track narrowing with recent increases in recording density, a structure for controlling the magnetization of a free magnetic layer by using a so-called exchange bias system is being the mainstream.

It is also known that when a specular layer (specular reflection layer) comprising a Ta oxide is provided for extending the mean free path λ+ of conduction electrons having, for example, up spin, both the rate (ΔR/R) of change in resistance and reproduced output can be improved.

The above-described magnetic sensing element having the specular layer and using the exchange bias system for controlling magnetization of the free magnetic layer is though to be a desired structure for realizing a higher recording density in future.

The structure of a conventional magnetic sensing element and a manufacturing method therefor will be described below.FIGS. 17 and 18are drawings respectively showing steps for manufacturing a conventional magnetic sensing element. Each of the figures is a sectional view of the magnetic sensing element taken along the side facing a recording medium.

In the step shown inFIG. 17, an antiferromagnetic layer2comprising, for example, a PtMn alloy, is formed on a substrate1, and a pinned magnetic layer3comprising a magnetic material, a nonmagnetic material layer4and a free magnetic layer5comprising a magnetic material are further laminated on the antiferromagnetic layer2. Furthermore, a specular layer (specular reflection layer)9is formed on the free magnetic layer5. The specular layer9is formed by first depositing a Ta film and then oxidizing the Ta film. The Ta film can easily be oxidized by air exposure.

Next, a lift-off resist layer10is formed on the specular layer9shown inFIG. 17, and the portions of the specular layer9, which are exposed on both sides of the resist layer10in the track width direction (the X direction shown in the drawing), are completely removed by ion milling. In this step, the free magnetic layer5below the specular layer9is also partially removed (portions shown by dotted lines).

In the next step shown inFIG. 18, a ferromagnetic layer11, a second antiferromagnetic layer12made of a IrMn alloy, or the like, and an electrode layer13are continuously deposited on each of the portions of the free magnetic layer5, which are exposed on both sides of the resist layer10. Then, the resist layer10shown inFIG. 18is removed.

In the magnetic sensing element shown inFIG. 18, a track width Tw can be defined by the distance between the ferromagnetic layers11in the track width direction (the X direction shown in the drawing), and the ferromagnetic layers11are strongly pinned in the X direction by an exchange coupling magnetic field produced between the ferromagnetic layers11and the second antiferromagnetic layers12. Therefore, both end portions A of the free magnetic layer5, which are respectively positioned below the ferromagnetic layers11, are strongly pinned in the X direction by ferromagnetic coupling with the ferromagnetic layers11, and the central portion B of the free magnetic layer5in the track width Tw region is possibly put into a single magnetic domain state to a weak level permitting reversal of magnetization with an external magnetic field.

However, the conventional magnetic sensing element formed in the manufacturing steps shown inFIGS. 17 and 18has the following problems:

(1) First, not only the specular layer9but also a portion of the free magnetic layer5formed below the specular layer9are removed during ion milling in the step shown inFIG. 17, and thus an inert gas such as Ar or the like, that is used for ion milling, easily enters the exposed portions of the free magnetic layer5from the surface. Therefore, the crystal structure of the surface portions5aof the free magnetic layer5is broken by damage due to the ion milling, or a crystal defect easily occurs in the structure (Mixing effect). Thus, the magnetic characteristics of the surface portions5aof the free magnetic layer5easily deteriorate.

It is most preferable that only the specular layer9can be removed without removal of the free magnetic layer5. However, it is difficult to actually control such ion milling.

A reason for this lies in the thickness of the specular layer9formed on the free magnetic layer5. As described above, the specular layer9is formed by depositing the Ta film, and then oxidizing the Ta film.

In the deposition step, the Ta film conventionally functions as an anti-oxidation layer for protecting the free magnetic layer5formed below the Ta film from oxidation, and when the Ta film is formed to an excessively small thickness, therefore, the free magnetic layer5cannot be appropriately protected from oxidation.

In the deposition step, the Ta film is formed to a thickness of as large as 10 Å or more, preventing the free magnetic layer5formed below the Ta film from being oxidized by air exposure.

However, when the Ta film is oxidized by air exposure, the thickness of the oxidized portion increases to increase the thickness of the specular layer9formed by oxidizing the Ta film to be larger than the thickness of the Ta film in the deposition step. As described above, when the Ta film having a thickness of 10 Å or more is formed in the deposition step, the specular layer9having a thickness of 20 Å or more is formed.

Therefore, in order to effectively remove both end portions of the specular layer9by milling in the step shown inFIG. 17, high-energy ion milling is required. High-energy ion milling has a high milling rate, and it is thus nearly impossible to stop milling at the moment when the thick specular layer9is completely removed by ion milling. Namely, as the energy increases, the need to provide a wide margin for a milling stop position increases. Therefore, the free magnetic layer5formed below the specular layer9is partially removed, and is easily excessively damaged by the high-energy ion milling to significantly deteriorate the magnetic characteristics.

(2) As described above, the surface of the free magnetic layer5exposed by ion milling is damaged by the ion milling to deteriorate the magnetic characteristics. Therefore, magnetic coupling (a ferromagnetic exchange interaction) with the ferromagnetic layers11laminated on the free magnetic layer5is not sufficient, and thus the ferromagnetic layers11must be formed to a large thickness.

However, when the ferromagnetic layers11are formed to a large thickness, exchange coupling magnetic fields produced between the ferromagnetic layers11and the antiferromagnetic layers12are weakened, failing to strongly fix magnetizations of both end portions A of the free magnetic layer5to produce the problem of side reading, and failing to manufacture a magnetic sensing element capable of complying with track narrowing.

When the ferromagnetic layers11are formed to an excessively large thickness, an excessive static magnetic field is easily applied to the central portion B of the free magnetic layer5from the inner side plane of each of the ferromagnetic layers11, thereby easily deteriorating the sensitivity of the central portion B of the free magnetic layer5to an external magnetic field, the central portion B permitting reversal of magnetization.

As described above, in the structure of the magnetic sensing element in which the specular layer9comprising a Ta oxide is formed on the free magnetic layer5, and the ferromagnetic layers11and the antiferromagnetic layers12are laminated on the portions of the free magnetic layer5, which are exposed by removing both end portions of the specular layer9, magnetization of the free magnetic layer5cannot be appropriately controlled, and a magnetic sensing element capable of complying with a narrower track cannot be manufactured.

SUMMARY OF THE INVENTION

Accordingly, the present invention has been achieved for solving the above problems of the conventional element, and an object of the present invention is to provide a magnetic sensing element comprising a specular layer, and capable of properly controlling the magnetization of a free magnetic layer in an exchange bias system and of appropriately complying with track narrowing, and a method of manufacturing the magnetic sensing element.

In a first aspect of the present invention, a magnetic sensing element comprises a first antiferromagnetic layer, a pinned magnetic layer, a nonmagnetic material layer, and a free magnetic layer, which are laminated in that order from below, a specular layer and a nonmagnetic layer which are provided on a central portion of the free magnetic layer in that order from below, and ferromagnetic layers and second antiferromagnetic layers which are provided, in that order from below, on both end portions of the free magnetic layer in the track width direction.

In the present invention, the thickness of the specular layer provided on the central portion of the free magnetic layer is preferably 3 Å to 10 Å.

In the present invention, the specular layer is preferably made of an oxide or nitride comprising at least one element selected from Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements. The term “the rare earth elements” is a general term for Sc, Y and the lanthanoide series.

In the present invention, the nonmagnetic layer preferably comprises at least one of Ru, Rh, Pd, Ir, Os, Re, Cr, Cu, Pt, and Au.

In the structure of the magnetic sensing element in the first aspect of the present invention, the nonmagnetic layer is formed on the specular layer formed on the central portion of the free magnetic layer. In this structure, the nonmagnetic layer functions as an antioxidation layer for appropriately protecting the free magnetic layer and the specular layer from oxidation. Therefore, even when the specular layer is thinly formed, a failure of oxidation of the free magnetic layer by air exposure does not occur. Also, the nonmagnetic layer comprises a metal hard to oxidize, thereby causing no problem in which the nonmagnetic layer is oxidized with oxygen diffusing from the specular layer to the nonmagnetic layer, and the specular layer is reduced to lose its specular effect.

In the present invention, the total thickness of the specular layer and the nonmagnetic layer, which are formed on the free magnetic layer, can be decreased, and thus the specular layer and the nonmagnetic layer can be removed from both end portions of the free magnetic layer by low-energy ion milling. Therefore, the damage to the surfaces of both end portions of the free magnetic layer by ion milling can be decreased, as compared with a conventional element.

Therefore, in the present invention, magnetizations of both end portions of the free magnetic layer can be effectively pinned by ferromagnetic coupling produced between the free magnetic layer and the ferromagnetic layers, and the central portion of the free magnetic layer can be weakly put into a single magnetic domain state at a level permitting magnetization reversal with an external magnetic field. It is thus possible to manufacture the magnetic sensing element comprising the specular layer and permitting appropriate control of the magnetization of the free magnetic layer even with a narrower track.

In a second aspect of the present invention, a magnetic sensing element comprises a first antiferromagnetic layer, a pinned magnetic layer, a nonmagnetic material layer, and a free magnetic layer, which are laminated in that order from below, a specular layer provided on a central portion of the free magnetic layer, and a ferromagnetic layer and a second antiferromagnetic layer, which are provided, in that order from below, on each end portion of the free magnetic layer in the track width direction, wherein the thickness of the specular layer provided on the central portion of the free magnetic layer is 3 Å to 15 Å.

In the present invention, the specular layer is preferably made of an oxide or nitride comprising at least one element from Cr, Mo, W, Ti, Si, Ge and Al.

Unlike in the structure of the magnetic sensing element in the first aspect, in the structure of the magnetic sensing element in the second aspect of the present invention, a nonmagnetic layer is not formed on the specular layer formed on the central portion of the free magnetic layer.

In the magnetic sensing element in the second aspect of the present invention, the specular layer itself functions as an antioxidation layer for protecting the free magnetic layer formed below the specular layer from oxidation by air exposure or the like. However, in the present invention, even when the specular layer comprising a Cr oxide or the like is formed to a small thickness of 3 Å to 15 Å, the function as the antioxidation layer can be properly imparted to the specular layer. In this way, in the present invention, the specular layer can be thinly formed, and can thus be removed from both end portions of the free magnetic layer by low-energy ion milling, thereby decreasing the damage to the surfaces of both sides of the free magnetic lay by ion milling, as compared with a conventional sensing element.

Therefore, in the present invention, magnetizations of both end portions of the free magnetic layer can be effectively pinned by ferromagnetic coupling produced between the free magnetic layer and the ferromagnetic layers, and the central portion of the free magnetic layer can be weakly put into a single magnetic domain state at a level permitting magnetization reversal with an external magnetic field. It is thus possible to manufacture the magnetic sensing element comprising the specular layer and permitting appropriate control of magnetization of the free magnetic layer even with a narrower track.

In a third aspect of the present invention, a magnetic sensing element comprises a first antiferromagnetic layer, a pinned magnetic layer, a nonmagnetic material layer, and a free magnetic layer, which are laminated in that order from below, a specular layer provided on a central portion of the free magnetic layer, and a ferromagnetic layer and a second antiferromagnetic layer, which are provided, in that order from below, on each end portion of the free magnetic layer in the track width direction, wherein the specular layer is made of an oxide or nitride comprising at least one element from Cr, Mo, W, Ti, Si, Ge and Al.

In the present invention, the thickness of the specular layer provided on the central portion of the free magnetic layer is 3 Å to 15 Å.

Unlike in the structure of the magnetic sensing element in the first aspect, in the structure of the magnetic sensing element in the third aspect of the present invention, a nonmagnetic layer is not formed on the specular layer formed on the central portion of the free magnetic layer.

In the magnetic sensing element in the third aspect of the present invention, the specular layer itself functions as an antioxidation layer, for protecting the free magnetic layer formed below the specular layer from oxidation by air exposure or the like. However, in the present invention, the specular layer comprises a Cr oxide or the like. Since oxidation of Cr by air exposure slowly proceeds, the free magnetic layer formed below the specular layer can be properly protected from oxidation by the specular layer even when the Cr film is thinly formed.

Therefore, the specular layer comprises Cr oxide or nitride, and thus the function as the antioxidation layer can be imparted to the free magnetic layer even when the specular layer is formed thinly in comparison with a conventional element. Thus, the thin specular layer can be removed from both end portions of the free magnetic layer by low-energy ion milling, thereby decreasing the damage to the surfaces of both end portions of the free magnetic lay by ion milling, as compared with the conventional sensing element.

Therefore, in the present invention, magnetizations of both sides of the free magnetic layer can be effectively pinned by ferromagnetic coupling produced between the free magnetic layer and the ferromagnetic layers, and the central portion of the free magnetic layer can be weakly put into a single magnetic domain state in a level permitting magnetization reversal with an external magnetic field. It is thus possible to manufacture the magnetic sensing element comprising the specular layer and permitting appropriate control of the magnetization of the free magnetic layer even with a narrower track.

In the present invention, the total thickness of the layers formed on the central portion of the free magnetic layer is preferably 20 Å or less. Therefore, the layers formed on each end portion of the free magnetic layer can be properly removed by low-energy ion milling in the step of ion milling the layers, and thus the surface of each end portion of the free magnetic layer can be effectively protected from damage by ion milling.

In the present invention, a backed layer may be formed between the specular layer and the central portion of the free magnetic layer. In this case, the backed layer may be formed on each end portion of the free magnetic layer, and the ferromagnetic layers may be respectively formed on the backed layers on both end portions.

In the present invention, the specular layer may be formed on each end portion of the free magnetic layer, and the ferromagnetic layers may be respectively formed on the specular layers on both end portions.

In the present invention, the thickness of each of the specular layers or the backed layers formed on both end portions is preferably 0.2 Å to 3 Å.

In the present invention, the backed layers or the specular layers are left on both end portions of the free magnetic layer, and thus the surfaces of both end portions of the free magnetic layer are not damaged by ion milling. Therefore, the magnetic properties of both end portions of the free magnetic layer can be maintained good.

In the present invention, the thickness of each of the backed layers or the specular layers formed on both end portions is decreased as much as possible (specifically, 0.2 Å to 3 Å) to produce ferromagnetic coupling between the ferromagnetic layers and both end portions of the free magnetic layer, thereby permitting proper control of the magnetization of the free magnetic layer.

In the present invention, each of the ferromagnetic layers on both end portions of the nonmagnetic layer is preferably formed to a thickness of 2 Å to 50 Å. Therefore, in the present invention, even when the ferromagnetic layers are thinly formed, ferromagnetic coupling can be produced between both end portions of the free magnetic layer and the ferromagnetic layers. In a conventional sensing element, the magnetic properties of both end portions of the free magnetic layer deteriorate due to the influence of ion milling, and thus the thicknesses of the ferromagnetic layers must be increased for maintaining sufficient ferromagnetic coupling with the free magnetic layer. In this case, exchange coupling magnetic fields produced between the ferromagnetic layers and the second antiferromagnetic layers are weakened, and an excessive static magnetic field is easily applied to the central portion of the free magnetic layer from the inner side surface of each of the ferromagnetic layers, thereby causing the problem of deteriorating sensitivity. The present invention can properly suppress this problem.

In the present invention, the free magnetic layer is preferably formed in a structure comprising three magnetic layers. Specifically, the free magnetic layer is preferably formed in a three-layer structure of CoFe/NiFe/CoFe.

A method of manufacturing a magnetic sensing element of the present invention comprises the following steps:

(a) the step of laminating a first antiferromagnetic layer, a pinned magnetic layer, a nonmagnetic intermediate layer, a free magnetic layer, a specular layer and a nonmagnetic layer on a substrate in turn from below;

(b) the step of performing first magnetic field annealing to produce an exchange coupling magnetic field between the first antiferromagnetic layer and the pinned magnetic layer, so that the magnetization of the pinned magnetic layer is pinned in a height direction;

(c) the step of forming a resist layer on a central portion of the nonmagnetic layer;

(d) the step of removing the portions of the nonmagnetic layer and the specular layer, which are exposed from both sides of the resist layer in the track width direction, forming ferromagnetic layers and second antiferromagnetic layers on both exposed portions of the free magnetic layer, and removing the resist layer; and

(e) the step of performing second magnetic field annealing to produce exchange coupling magnetic fields between the second antiferromagnetic layers and the ferromagnetic layers, so that magnetization of each end portion of the free magnetic layer is pinned in a direction crossing the magnetization direction of the pinned magnetic layer.

In the present invention, in the step (a), the thickness of the specular layer is preferably 3 Å to 10 Å.

In the present invention, the specular layer is preferably made of an oxide or nitride comprising at least one element selected from Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements.

In the present invention, the specular layer is preferably formed by forming an element film comprising at least one element of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements, and then oxidizing the element film in a vacuum container. As the oxidization method, a method of natural oxidization, radical oxidization, plasma oxidization, or the like can be used.

In the present invention, the nonmagnetic layer preferably comprises at least one of Ru, Rh, Pd, Ir, Os, Re, Cr, Cu, Pt, and Au. The specular layer and the nonmagnetic layer are preferably formed in the vacuum container.

In the present invention, in the step (a), the specular layer and the nonmagnetic layer are formed on the free magnetic layer. In the present invention, the nonmagnetic layer functions as an antioxidation layer for protecting the free magnetic layer (and the specular layer) from oxidization by air exposure, and thus the specular layer can be thinly formed.

As described above, the specular layer is formed by, for example, oxidization or nitriding in the vacuum container, and thus the oxidation or nitriding rate in the vacuum container can be decreased. Therefore, even when the specular layer is formed to a small thickness, there is no defect that oxidization reaches the free magnetic layer formed below the specular layer.

As described above, the nonmagnetic layer comprises, for example, a material hard to oxidize, such as Ru or the like, and even when the nonmagnetic layer is thinly formed like the specular layer, the nonmagnetic layer can thus exhibit the sufficient function as the anti-oxidation layer. Like the specular layer, the nonmagnetic layer is continuously formed in the vacuum container, thereby appropriately protecting the free magnetic layer and the specular layer from oxidation by air exposure.

As described above, in the present invention, the total thickness of the specular layer and the nonmagnetic layer formed on the free magnetic layer can be decreased, and thus the specular layer and the nonmagnetic layer can be removed from both end portions of the free magnetic layer by low-energy ion milling in the step (d).

Therefore, in the step (d), the surfaces of both sides of the free magnetic layer are less damaged by ion milling, and thus the magnetic properties of both sides of the free magnetic layer can be maintained good. Therefore, for example, ferromagnetic coupling between both sides of the free magnetic layer and the ferromagnetic layers can be effectively increased, thereby permitting proper control of magnetization of the free magnetic layer as compared with a conventional sensing element.

Therefore, in the present invention, it is possible to manufacture the magnetic sensing element comprising the specular layer and having good reproduction sensitivity and excellent reproduction properties.

A method of manufacturing a magnetic sensing element of the present invention comprises the following steps:

(f) the step of laminating a first antiferromagnetic layer, a pinned magnetic layer, a nonmagnetic intermediate layer, a free magnetic layer, and a specular layer on a substrate in turn from below, the specular layer being made of an oxide or nitride comprising at least one element selected from Cr, Mo, W, Ti, Si, Ge and Al;

(g) the step of performing first magnetic field annealing to produce an exchange coupling magnetic field between the first antiferromagnetic layer and the pinned magnetic layer, so that the magnetization of the pinned magnetic layer is pinned in a height direction;

(h) the step of forming a resist layer on a central portion of the nonmagnetic layer;

(i) the step of removing the portions of the specular layer, which are exposed from both sides of the resist layer in the track width direction, forming ferromagnetic layers and second antiferromagnetic layers on both exposed portions of the free magnetic layer, and removing the resist layer; and

(j) the step of performing second magnetic field annealing to produce exchange coupling magnetic fields between the second antiferromagnetic layers and the ferromagnetic layers, so that the magnetization of each end portion of the free magnetic layer is pinned in a direction crossing the magnetization direction of the pinned magnetic layer.

In the present invention, in the step (f), the thickness of the specular layer is preferably 3 Å to 15 Å.

In the present invention, in the step (f), the specular layer made of a Cr oxide or the like is formed on the free magnetic layer. Since a Cr film is a dense film hard to oxidize by air exposure, and thus even when a Cr thin film is formed in the deposition step, the free magnetic layer formed below the Cr film can be appropriately protected from oxidization by air exposure.

Furthermore, the Cr film or the like can be thinly formed, and even when the specular layer is formed by oxidizing the Cr film, the thickness of the specular layer is not much increased as compared with that in deposition, maintaining the thin specular layer. Therefore, in removing the specular layer from both end portions of the free magnetic layer by ion milling in the step (i), the specular layer can be removed by low-energy ion milling.

Therefore, in the step (i), the surfaces of both sides of the free magnetic layer are less damaged by ion milling, and thus the good magnetic properties of the both sides of the free magnetic layer can be maintained. Consequently, for example, ferromagnetic coupling between both sides of the free magnetic layer and the ferromagnetic layers can be effectively increased to permit proper control of the magnetization of the free magnetic layer, as compared with a conventional sensing element.

Therefore, in the present invention, the magnetic sensing element having the specular layer and exhibiting good reproduction sensitivity and excellent reproduction characteristics even with a narrower track can be manufactured.

In the present invention, in the step (a) or (f), the total thickness of the layers formed on the free magnetic layer is preferably 20 Å or less. Therefore, in the step (d) or (i), the layers on both end portions of the free magnetic layer can be effectively removed even by low-energy ion milling, and the surfaces of both end portions of the free magnetic layer can be protected from damage by ion milling, thereby maintaining the magnetic characteristics of both end portions of the free magnetic layer in a good state.

In the present invention, in the step (a) or (f), a backed layer may be formed on the free magnetic layer, and the specular layer may be formed on the backed layer.

In this case, in the step (d) or (i), the backed layer may be partially left on both sides of the free magnetic layer so that the ferromagnetic layers are formed on the remaining portions of the backed layer.

In the present invention, in the step (d) or (i), the specular layer may be partially left on both sides of the free magnetic layer so that the ferromagnetic layers are formed on the remaining portions of the specular layer.

In the present invention, the thickness of the remaining portions of the backed layer or the specular layer is preferably 0.2 Å to 3 Å.

As described above, when the specular layer or the backed layer is partially left on both end portions of the free magnetic layer, the both end portions of the free magnetic layer formed below the specular layer or the backed layer can be effectively protected from ion milling, thereby maintaining the magnetic characteristics of both sides of the free magnetic layer in a good state. Also, in the present invention, the backed layer or the specular layer is left thinly on both sides, and for example, the ferromagnetic layers and both end portions of the free magnetic layer can thus be effectively ferromagnetically coupled with each other.

In the present invention, in the step (d) or (i), each of the ferromagnetic layers is formed to a thickness of 2 Å to 50 Å.

In the present invention, in the step (a) or (f), the free magnetic layer is preferably form in a structure comprising three magnetic layers. Specifically, the free magnetic layer is preferably formed in the three-layer structure of CoFe/NiFe/CoFe.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1is a partial sectional view of the structure of a magnetic sensing element (spin-valve thin film element) according to a first embodiment of the present invention, taken along the side facing a recording medium.

The magnetic sensing element shown inFIG. 1detects a leakage magnetic field from the recording medium such as a hard disk or the like by using a magnetoresistive effect to read record signals.

InFIG. 1, reference numeral20denotes a substrate. A seed layer21made of a NiFe alloy, a NiFeCr alloy or Cr is formed on the substrate20. The seed layer21is formed to have, for example, the composition (Ni0.8Fe0.2)60 at %Cr40 at %and a thickness of 60 Å. In the magnetic sensing element, an underlying layer made of Ta may be formed below the seed layer21(between the seed layer21and the substrate20).

A first antiferromagnetic layer23is formed on the seed layer21. The first antiferromagnetic layer23is made of a PtMn alloy, a X—Mn (wherein X is at least one element of Pd, Ir, Rh, Ru, Os, Ni, and Fe) alloy, or a Pt—Mn—X′ (wherein X′ is at least one element of Pd, Ir, Rh, Ru, Au, Ag, Os, Cr, Ni, Ar, Ne, Xe and Kr) alloy.

The first antiferromagnetic layer23formed by using such an alloy is heat-treated to obtain an exchange coupling film which produces a large exchange coupling magnetic field between the first antiferromagnetic layer23and a pinned magnetic layer24. Particularly, in use of the PtMn alloy, the excellent exchange coupling film having an exchange coupling magnetic field of 48 kA/m or more, for example, over 64 kA/m, between the first antiferromagnetic layer23and the pinned magnetic layer24, and a blocking temperature of as high as 380° C., at which the exchange coupling magnetic field is lost, can be obtained.

Any one of the alloys has a disordered face-centered cubic structure (fcc) immediately after deposition, but the structure is transformed to a CuAuI-type ordered face-centered tetragonal structure (fct) by heat treatment.

The thickness of the first antiferromagnetic layer23near the center of the track width direction (the X direction shown in the drawing) is 80 to 300 Å.

As shown inFIG. 1, the pinned magnetic layer24is formed on the first antiferromagnetic layer23. The pinned magnetic layer24has a synthetic ferrimagnetic structure. The pinned magnetic layer24has a three-layer structure comprising magnetic layers24aand24c, and a nonmagnetic intermediate layer24bprovided between the magnetic layers24aand24c.

Each of the magnetic layers24aand24cis made of a magnetic material, for example, a NiFe alloy, Co, a CoNiFe alloy, a CoFe alloy, a CoNi alloy, or the like. The magnetic layers24aand24care preferably formed by using the same material.

The nonmagnetic intermediate layer24bis preferably made of an alloy comprising at least one of Ru, Rh, Ir, Cr, Re and Cu. Particularly, the nonmagnetic intermediate layer24bis preferably made of Ru.

Furthermore, a nonmagnetic material layer25is formed on the pinned magnetic layer24. The nonmagnetic material layer25is a layer for preventing magnetic coupling between the pinned magnetic layer24and a free magnetic layer26, and a sensing current mainly flows through the nonmagnetic material layer25. The nonmagnetic material layer25is preferably made of a conductive nonmagnetic material such as Cu, Cr, Au, Ag, or the like, and more preferably made of Cu.

Furthermore, the free magnetic layer26is formed on the nonmagnetic material layer25. In the embodiment shown inFIG. 1, the free magnetic layer26has a two-layer structure. A layer denoted by reference numeral26ais an anti-diffusion layer comprising Co or CoFe. Furthermore, a magnetic material layer26bmade of a NiFe alloy or the like is formed on the anti-diffusion layer26a.

A backed layer27made of Cu or the like is formed on the free magnetic layer26. The backed layer27is formed over the entire surface of the free magnetic layer26. However, in this embodiment, the thickness of the central portion27aof the backed layer27is larger than the thickness of each of both end portions27bof the backed layer27, which are formed on both end portions C of the free magnetic layer26.

Furthermore, ferromagnetic layers28are respectively formed on both end portions27bof the backed layer27, and second antiferromagnetic layers29are respectively formed on the ferromagnetic layers28. Like the first antiferromagnetic layer23, each of the second antiferromagnetic layers29is made of a PtMn alloy, a X—Mn (wherein X is at least one element of Pd, Ir, Rh, Ru, Os, Ni, and Fe) alloy, or a Pt—Mn—X′ (wherein X′ is at least one element of Pd, Ir, Rh, Ru, Au, Ag, Os, Cr, Ni, Ar, Ne, Xe and Kr) alloy.

Furthermore, electrode layers30are respectively formed on the second antiferromagnetic layers29. Each of the electrode layers30is made of, for example, Au, W, Cr, Ru, Rh, or Ta.

As shown inFIG. 1, a specular layer31is formed on the central portion27aof the backed layer27, and a nonmagnetic layer32is further formed on the specular layer31.

In the embodiment shown inFIG. 1, the upper surfaces28aof the ferromagnetic layers28, the upper surfaces29aof the second antiferromagnetic layers29, and the upper surfaces30aof the electrode layers30are inclined or curved surfaces so that the distance between both surfaces gradually increases in the direction (the Z direction shown in the drawing) from the lower side to the upper side.

The structural characteristics of the magnetic sensing element shown inFIG. 1are described below.

The function of the specular layer31shown inFIG. 1is first described. In the present invention, the specular layer (also referred to as the “specular reflection layer”)31comprises, for example, an oxide or nitride of Cr or the like. When the specular layer31is formed above the free magnetic layer26, conduction electrons (for example, up-spin conduction electrons) reaching the specular layer31are specular-reflected by the specular layer31while maintaining their spin states (energy, quantum state, etc.). The up-spin conduction electrons specular-reflected are changed in the motion direction so that they can pass through the free magnetic layer.

Therefore, in the present invention, the mean free path λ+ of up-spin conduction electrons can be extended by providing the specular layer31, as compared with a conventional path, thereby increasing the difference between the mean free path λ+ of up-spin conduction electrons and the mean free path λ− of down-spin conduction electrons. It is thus possible to improve the rate (ΔR/R) of change in resistance, and reproduced output.

Next, the material of the specular layer31is described below. In the present invention, the specular layer31is preferably made of an oxide or nitride comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements. The term “the rare earth elements” is a general term for Sc, Y and the lanthanoide series. The specular layer31made of an oxide or nitride of at least one element selected from the above elements can appropriately exhibit the specular effect.

In the present invention, the thickness of the specular layer31can be decreased, as compared with a conventional example. In the present invention, the specular layer31is preferably formed to a thickness of 3 Å to 10 Å on the central portion D of the free magnetic layer26. In the present invention, the first reason why the specular layer31can be formed to such a small thickness lies in the point that the material and the treatment method (oxidization method or nitriding method) of the specular layer31are optimized, and the second reason lies in point that the nonmagnetic layer32is formed on the specular layer31.

The specular layer31is made of an oxide or nitride comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements. However, in the present invention, the specular layer31is formed by, for example, forming an element thin film of about 1 to 5 Å comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements in the deposition step, and then oxidizing or nitriding the element film at low pressure in a vacuum chamber. As the oxidization method, natural oxidation, radical oxidation or plasma oxidation can be selected.

When the element film is oxidized or nitrided at low temperature, the oxidization rate or nitriding rate can be decreased, and even when the specular layer31is thinly formed, oxidation or nitriding can be prevented from reaching the backed layer27and the free magnetic layer26, which are formed below the specular layer31.

Although the thickness of the specular layer31formed by oxidizing or nitriding the element film is increased to be larger than the element film, the specular layer31is formed to a thickness of only 3 Å to 10 Å even by oxidization or nitriding because the element film has a thickness of as small as about 1 Å to 5 Å.

In the present invention, the material and the treatment method of the specular layer31are optimized so that oxidization or nitriding of the backed layer27and the free magnetic layer26formed below the specular layer31can be appropriately prevented even when the specular layer31is formed to a thickness of as small as 3 Å to 10 Å.

As described above, the second reason why the specular layer31can be thinly formed lies in the point that the nonmagnetic layer32is formed on the specular layer31. In the present invention, the nonmagnetic layer32preferably comprises at least one of Ru, Rh, Pd, Ir, Os, Re, Cr, Cu, Pt and Au.

The nonmagnetic layer32comprising Ru is a dense film hard to oxidize by air exposure, and thus the specular layer31formed below the nonmagnetic layer32, and the backed layer27and the free magnetic layer26formed below the specular layer31are appropriately protected from oxidization by the nonmagnetic layer32.

A conventional specular layer31comprising a Ta oxide also functions as an anti-oxidization layer for protecting a free magnetic layer, which is formed below the specular layer31, from oxidization, and thus the specular layer31must be formed to a thickness of as large as 20 Å or more. In the present invention, however, the nonmagnetic layer32is formed on the specular layer31to charge the nonmagnetic layer32with the function as the anti-oxidization layer. Consequently, even when the thickness of the specular layer31is decreased, each of the backed layer27and the free magnetic layer26formed below the specular layer31can be appropriately protected from oxidization by air exposure.

The nonmagnetic layer32made of Ru or the like as described above is a dense film hard to oxidize, and thus even when the nonmagnetic layer32is formed to a small thickness in the present invention, the specular layer31, etc. formed below the nonmagnetic layer32can be appropriately protected from oxidization. There is also no problem in which oxygen contained in the specular layer31diffuses to the nonmagnetic layer32to oxidize the nonmagnetic layer32in the annealing step, and the specular layer is reduced to lose its specular effect.

In the present invention, the nonmagnetic layer32is preferably formed to a thickness of 2 Å to 8 Å. With the nonmagnetic layer32having a thickness of less than 2 Å, each of the layers formed below the nonmagnetic layer32cannot be effectively protected from oxidization. With the nonmagnetic layer32having a thickness of over 8 Å, the backed layer27, the specular layer31and the nonmagnetic layer32are formed to a total thickness h1of 20 Å or more on each of both end portions C of the free magnetic layer26in the deposition step. Therefore, both end portions C of the free magnetic layer26are easily affected by ion milling to undesirably deteriorate the magnetic characteristics of both end portions of the free magnetic layer26.

In the manufacturing method described below, like the specular layer31, the nonmagnetic layer32is preferably continuously formed in a vacuum container.

As described above, the specular layer31is formed by oxidization or nitriding under low pressure, and the nonmagnetic layer32is formed on the specular layer31, so that the specular layer can be formed to a small thickness. In the present invention, for example, Ta which is conventionally used can be used as the material for the specular layer31.

In the present invention, a Ta film is formed to a thickness of as small as 1 Å to 5 Å in the deposition step. The Ta film is easily oxidized by air exposure, and with such a Ta thin film, the free magnetic layer26formed below the Ta film is easily affected by oxidization. Therefore, the Ta film is oxidized or nitrided under low pressure in the vacuum container. In this case, the rate of oxidization or nitriding under low pressure is lower than that in the air, and thus only the Ta thin film of 1 Å to 5 Å can be appropriately oxidized or nitrided while preventing the influence of oxidization or nitriding on the free magnetic layer26and the backed layer27formed below the Ta film.

In the present invention, next, the nonmagnetic layer32made of Ru or the like is continuously formed on the specular layer31comprising an oxide or nitride of the Ta film without being exposed to the air so that the specular layer31is appropriately protected from oxidization by air exposure. Without the nonmagnetic layer32, oxidization of the specular layer31comprising an oxide or nitride of the Ta film significantly proceeds, and thus the free magnetic layer26and the backed layer27formed below the specular layer31are affected by oxidization.

When the specular layer31is formed by using an oxide or nitride of a material, for example, Cr, Mo, W, Ti, Si, Ge or Al, in which oxidization less proceeds by air exposure as compared with Ta, even with a thin Cr film or the like, the free magnetic layer26and the backed layer27formed below the specular layer31can be appropriately prevented from being oxidized by air exposure. Therefore, the Cr film or the like may be oxidized in the air without using the low-pressure oxidization method.

By forming the backed layer27, the mean free path of up-spin conduction electrons which contribute to the magnetoresistive effect can be extended, and a high rate of change in resistance can be obtained by a spin filter effect in the magnetic sensing element, thereby making the magnetic sensing element adaptable to a higher recording density.

The backed layer27comprises, for example, Cu, Ag, Au, Ru, or the like. The thickness of the central portion27aof the backed layer27is preferably 2 Åto 5 Å. Therefore, the spin filter effect can be exhibited, and the influence of ion milling on both end portions C of the free magnetic layer26can be decreased.

In the embodiment shown inFIG. 1, the thickness of each of both end portions27bof the backed layer27is smaller than the central portion27a. However, if the thickness of the central portion27aof the backed layer27is as small as 3 Å or less, the thickness of each of both end portions27bof the backed layer27may be the same as the central portion27a.

Next, the total thickness of the layers formed on the central portion D of the free magnetic layer26is described below.

In the embodiment shown inFIG. 1, the backed layer27, the specular layer31and the nonmagnetic layer32are formed on the central portion D of the free magnetic layer26. In the present invention, the total thickness h1of these layers formed on the central portion D of the free magnetic layer26is preferably 7 Å to 20 Å. The reason for setting the minimum of the total thickness h1to 7 Å is that the minimum thickness of the backed layer27is 2 Å, the minimum thickness of the specular layer31is 3 Å, and the minimum thickness of the nonmagnetic layer32is 2 Å.

In the present invention, when the total thickness of the layers formed on the central portion D of the free magnetic layer26is 20 Å or less, each of the layers formed on each end portion C of the free magnetic layer26can be removed by low-energy ion milling in the ion milling step. The low-energy milling rate is lower than that in high-energy milling, and thus milling can be relatively easily controlled to be stopped in a stage in which both end portions27bof the backed layer27are slightly left, as shown in FIG.1.

In the embodiment shown inFIG. 1, both end portions27bof the backed layer27are partially left on both sides C of the free magnetic layer26, and the ferromagnetic layers28are formed on both end portions27b. Namely, inFIG. 1, both end portions27bof the backed layer27are interposed between both end portions C of the free magnetic layer26and the ferromagnetic layers28. However, both end portions27bof the backed layer27are preferably formed to a thickness of as small as 0.2 Å to 3 Å. The thickness “0.2 Å” is the average over the whole of both end portions27bof the backed layer27. The thickness of 0.2 Å is smaller than the thickness of an atomic layer, and thus in both end portions27b, a portion having the constituent atoms of the backed layer27and a portion without the constituent atoms are islanded. Therefore, the thickness “0.2 Å” is the average over the whole of both end portions27bof the backed layer27.

As described above, each of both end portions27bof the backed layer27is formed to a thickness of as small as 0.2 Å to 3 Å, so that ferromagnetic coupling occurs between both end portions C of the free magnetic layer26and the ferromagnetic layers28. The ferromagnetic layers28are strongly put into a single magnetic domain state in the track width direction (the X direction) by exchange coupling magnetic fields produced between the ferromagnetic layers28and the second antiferromagnetic layers29respectively formed thereon. As a result, both end portions C of the free magnetic layer26on which ferromagnetic coupling with the ferromagnetic layers28is exerted are also oriented in the same direction as the magnetization directions of the ferromagnetic layers28, and strongly put into a single magnetic domain state in the track width direction (the X direction).

The term “ferromagnetic coupling” represents that the magnetization of each of both end portions C of the free magnetic layer26is oriented in the same direction as the magnetization directions of the ferromagnetic layers28by RKKY ferromagnetic coupling between both end portions C of the free magnetic layer26and the ferromagnetic layers28through both end portions27bof the backed layer27, or a direct exchange interaction through defects such as pin holes or the like, which are formed in both end portions27bof the backed layer27.

The constituent element of both end portions27bof the backed layer27thermally diffuses by annealing in a magnetic field for producing exchange coupling magnetic fields between the ferromagnetic layers28and the second antiferromagnetic layers29. For example, when each of the ferromagnetic layers28and the free magnetic layer26comprises a NiFe alloy, and the backed layer27comprises Cu, and particularly, when both end portions27bof the backed layer27are formed to a very small thickness, both end portions27bof the backed layer27disappear by the thermal diffusion, and a NiFeCu alloy layer is formed on each of the backed layer side surfaces of the free magnetic layer and the ferromagnetic layers28. Therefore, both end portions C of the free magnetic layer26and the ferromagnetic layers28function as an integrated ferromagnetic layer.

Therefore, when the magnetizations of the ferromagnetic layers28are pinned in the track width direction (the X direction) by the exchange coupling magnetic fields produced between the ferromagnetic layers28and the antiferromagnetic layers29, both end portions C of the free magnetic layer26are oriented in the same direction as the magnetization directions of the ferromagnetic layers28, and strongly put into the single magnetic domain state in the track width direction (the X direction).

In the present invention, each of the ferromagnetic layers28is preferably formed to a thickness of 2 Å to 50 Å.

In the present invention, even when the ferromagnetic layers28are thinly formed, the ferromagnetic coupling can be effectively produced between the ferromagnetic layers28and both end portions C of the free magnetic layer26. This is because both end portions C of the free magnetic layer26maintain the proper magnetic properties without being affected by ion milling. When each of the ferromagnetic layers28is formed to the above-described small thickness, large exchange coupling magnetic fields can be produced between the ferromagnetic layers28and the second antiferromagnetic layers29. Furthermore, it is possible to appropriately suppress a problem in which an excessive static magnetic field from the inner side face of each of the ferromagnetic layers28affects the central portion D of the free magnetic layer26, deteriorating the sensitivity of the free magnetic layer26.

As described above, in the embodiment shown inFIG. 1, the magnetization of each end portion C of the free magnetic layer26is appropriately fixed in the track width direction (the X direction).

On the other hand, the magnetization of the central portion D of the free magnetic layer26is weakly put into the single magnetic domain state in a level permitting reversal of magnetization. The width dimension of the central portion D in the track width direction (the X direction) substantially coincides with the track width Tw defined by the distance between the lower surfaces of the ferromagnetic layers28in the track width direction (the X direction). Therefore, even when narrowing of the track progresses with increases in the recording density, the region of the track width Tw can be properly defined as a sensitive region permitting reversal of magnetization, and the magnetic sensing element having the specular layer31and capable of appropriately complying with a higher recording density can be manufactured. The track width is preferably 0.2 μm or less.

FIG. 2is a partial sectional view of the structure of a magnetic sensing element according to a second embodiment of the present invention, as viewed from the side facing a recording medium.

In the embodiment shown inFIG. 2, the forms of layers are the same as the embodiment shown inFIG. 1except the backed layer27. Therefore, the form of the backed layer27is mainly described below.

InFIG. 2, the backed layer27is formed only on the central portion D of a free magnetic layer26, without being formed on both end portions C of the free magnetic layer26. As described above with reference toFIG. 1, the total thickness h1of the backed layer27, the specular layer31and the nonmagnetic layer32, which are formed on the free magnetic layer26, is 7 Å to 20 Å.

Therefore, in the present invention, in the step of removing the backed layer27, the specular layer31and the nonmagnetic layer32from both end portions C of the free magnetic layer26, only the backed layer27, the specular layer31and the nonmagnetic layer32can be appropriately removed even by low-energy ion milling.

Namely, in the present invention, low-energy ion milling can be used, and thus the milling rate can be decreased to be lower than that of high-energy milling to permit the removal of only the backed layer27, the specular layer31and the nonmagnetic layer32. Therefore, milling can be properly controlled to minimize damage to both end portions C of the free magnetic layer26by ion milling.

Therefore, in the embodiment shown inFIG. 2, both end portions C of the free magnetic layer26are less damaged by ion milling, and thus the magnetic properties of both end portions C of the free magnetic layer26can be maintained in a good state. Furthermore, the ferromagnetic layers28and the second antiferromagnetic layers29are formed on both end portions C of the free magnetic layer26, and the magnetizations of the ferromagnetic layers28are strongly pinned in the track width direction by exchange coupling magnetic fields between the ferromagnetic layers28and the antiferromagnetic layers29. As a result, the magnetizations of both end portions C of the free magnetic layer26ferromagnetically coupled with the ferromagnetic layers28can be strongly put into the single magnetic domain state in the track width direction.

Therefore, in the present invention, even with a narrower tack, the magnetization of the free magnetic layer26can be effectively controlled, and the magnetic sensing element having the specular layer31and excellent for a higher recording density can be manufactured.

In the embodiment shown inFIG. 2, the materials and the thicknesses of the other layers are the same as the embodiment shown inFIG. 1except the backed layer. Thus, a detailed description of the other layers is omitted (refer to FIG.1).

FIG. 3is a partial sectional view of the structure of a magnetic sensing element according to a third embodiment of the present invention, as viewed from the side facing a recording medium.

The embodiment shown inFIG. 3is different from the embodiments shown inFIGS. 1 and 2in that the backed layer27is not formed on the free magnetic layer26. InFIG. 3, the specular layer31and the nonmagnetic layer32are formed on the free magnetic layer26.

In the embodiment shown inFIG. 3, the thickness of the central portion31aof the specular layer31is larger than that of its each end portion31b.

As described above with reference toFIG. 1, the specular layer31is preferably made of an oxide or nitride comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements.

The thickness of the central portion31aof the specular layer31is preferably 3 Å to 10 Å.

In the present invention, the nonmagnetic layer32is formed as an anti-oxidation layer on the specular layer31, so that even with the specular layer31having a thickness of as small as 3 Å to 10 Å, the specular layer31and the free magnetic layer26can be appropriately protected from oxidization by air exposure. When the nonmagnetic layer32comprises a dense film of Ru or the like, which is hard to oxidize, even with the nonmagnetic layer32having a thickness of as small as 2 Å to 8 Å, the specular layer31and the free magnetic layer26can be appropriately protected from oxidization by air exposure. Therefore, in the present invention, the total thickness h2of the specular layer31and the nonmagnetic layer32formed on the central portion D of the free magnetic layer26can be decreased. In the present invention, the total thickness h2is preferably 5 Å to 20 Å. The reason for setting the minimum of the total thickness h2to 5 Å is that the minimum thickness of the specular layer is 3 Å, and the minimum thickness of the nonmagnetic layer32is 2 Å.

In this way, when the total thickness h2of the specular layer31and the nonmagnetic layer32formed on the central portion D of the free magnetic layer26is 20 Å or less, the specular layer31and the nonmagnetic layer32can be removed from both end portions C of the free magnetic layer26by using low-energy ion milling in the ion milling step after deposition of the specular layer31and the nonmagnetic layer32. Thus, the ion milling can easily be controlled to stop at a predetermined position.

In the embodiment shown inFIG. 3, both end portions31bof the specular layer31are left on both end portions C of the free magnetic layer26. However, the thickness of each of both end portions31bof the specular layer31is as small as 0.2 Å (the average over the whole of both end portions31b) to 3 Å. When such thin ends31bof the specular layer31are left, ferromagnetic coupling can be property produced between both end portions C of the free magnetic layer26and the ferromagnetic layers28, both end portions C respectively facing the ferromagnetic layers28with both end portions31bof the specular layer31provided therebetween. Alternatively, both end portions C of the free magnetic layer26and the ferromagnetic layers28can be caused to function as an integrated ferromagnetic layer, and both end portions C of the free magnetic layer26can be effectively put into the single magnetic domain state in the track width direction (the X direction).

On the other hand, the central portion D of the free magnetic layer26is weakly put into the single magnetic domain state in a level permitting reversal of magnetization with an external magnetic field.

In the embodiment shown inFIG. 3, it is possible to manufacture the magnetic sensing element having the specular layer31and capable of effectively controlling the magnetization of the free magnetic layer26even when the track is narrowed in future.

When the thickness of the central portion31aof the specular layer31formed on the central portion D of the free magnetic layer26is as small as 3 Å or less, the thickness of the central portion31amay be the same as the thicknesses of both end portions31b.

A description of the thicknesses and the material of layers not described above with reference toFIG. 3are described above with reference toFIG. 1(refer to FIG.1).

FIG. 4is a partial sectional view of the structure of a magnetic sensing element according to a fourth embodiment of the present invention, as viewed from the side facing a recording medium.

In the embodiment shown inFIG. 4, the forms of layers are the same as the embodiment shown inFIG. 3except the specular layer31. Therefore, the specular layer31is mainly described below.

InFIG. 4, the specular layer31is formed only on the central portion D of the free magnetic layer26, without being formed on both end portions C of the free magnetic layer26. As described above with reference toFIG. 3, the total thickness h2of the specular layer31and the nonmagnetic layer32formed on the central portion D of the free magnetic layer26is 5 Å to 20 Å.

Therefore, in the present invention, the specular layer31and the nonmagnetic layer32can be appropriately removed from both end portions C of the free magnetic layer26even by using low-energy ion milling in the ion milling step.

Namely, in the present invention, low-energy ion milling is used, and thus the milling rate can be decreased to be lower than that of high-energy milling to permit the removal of only the specular layer31and the nonmagnetic layer32. Therefore, milling can be properly controlled to minimize damage to both end portions C of the free magnetic layer26by ion milling.

Therefore, in the embodiment shown inFIG. 4, both end portions C of the free magnetic layer26are less damaged by ion milling, and thus the magnetic properties of both end portions C of the free magnetic layer26can be maintained in a good state. Furthermore, the ferromagnetic layers28and the second antiferromagnetic layers29are formed on both end portions C of the free magnetic layer26, and magnetizations of the ferromagnetic layers28are strongly pinned in the track width direction by exchange coupling magnetic fields between the ferromagnetic layers28and the antiferromagnetic layers29. As a result, magnetizations of both end portions C of the free magnetic layer26ferromagnetically coupled with the ferromagnetic layers28can be strongly put into the single magnetic domain state in the track width direction.

Therefore, in the present invention, even with a narrower track, the magnetization of the free magnetic layer26can be effectively controlled, and the magnetic sensing element having the specular layer31and excellent for a higher recording density can be manufactured.

In the embodiment shown inFIG. 4, the materials and the thicknesses of the other layers are the same as the embodiment shown inFIG. 3except the form of the specular layer31. Thus, a detailed description of the other layers is omitted (refer to FIGS.1and3).

FIG. 5is a partial sectional view of the structure of a magnetic sensing element according to a fifth embodiment of the present invention, as viewed from the side facing a recording medium.

Unlike in the embodiments shown inFIGS. 1to4, in the embodiment shown inFIG. 5, the nonmagnetic layer32is not formed on the specular layer31. InFIGS. 1to4, the reason for forming the nonmagnetic layer32is to cause the nonmagnetic layer32to function as the anti-oxidation layer. However, in the embodiment shown inFIG. 5, the specular layer31itself has the specular effect and the function as the anti-oxidization layer for protecting the free magnetic layer26and the backed layer27from oxidization by air exposure.

In the present invention, in order that the specular layer31functions as the anti-oxidization layer, even with a small thickness, the specular layer31must function as the anti-oxidization layer. Therefore, an oxide or nitride of Ta, which can be used in the embodiment shown inFIG. 4, cannot be used for the specular layer31in the embodiment shown in FIG.5. This is because with the specular layer31having a small thickness and comprising a Ta oxide or nitride, the backed layer27and the free magnetic layer26formed below the specular layer31are oxidized by air exposure.

The specular layer31used in the embodiment shown inFIG. 5must be made of a material having the property that oxidization by air exposure does not easily proceed deep. In the present invention, the specular layer31is preferably made of an oxide or nitride comprising at least one of Cr, Mo, W, Ti, Si, Ge and Al.

The specular layer31comprising such a material comprises a dense layer having a low rate of oxidization by air exposure. For example, even when a Cr thin film is formed on the backed layer27in the deposition step, the Cr film has a low rate of oxidization by air exposure, and can thus minimize the influence of oxidization by air exposure on the packed layer27and the free magnetic layer formed below the Cr film.

In the present invention, the specular layer31made of an oxide or nitride comprising at least one of Cr, Mo, W, Ti, Si, Ge and Al is preferably formed to a thickness of 3 Å to 15 Å. The specular layer31having a thickness of less than 3 Å is undesirable because the backed layer27and the free magnetic layer26are easily oxidized through the specular layer31. On the other hand, with the specular layer31having a thickness of over 15 Å, the total thickness h3of the backed layer27and the specular layer31formed on both end portions C of the free magnetic layer26in the deposition step becomes 20 Å or more. Therefore, in some cases, the specular layer31and the backed layer27cannot be completely removed from both end portions C of the free magnetic layer26by low-energy ion milling. As a result, conventional high-energy ion milling must be used, and thus both end portions C of the free magnetic layer26are undesirably easily damaged by ion milling.

In the embodiment shown inFIG. 5, the total thickness h3of the backed layer27and the specular layer31formed on the central portion D of the free magnetic layer26is preferably 5 Å to 20 Å. The reason for setting the minimum of the total thickness h3to 5 Å is that the minimum thickness of the backed layer27is 2 Å, and the minimum thickness of the specular layer31is 3 Å.

In the present invention, when the total thickness h3is 20 Å or less, the backed layer27and the specular layer31can be removed from both end portions C of the free magnetic layer26by using low-energy ion milling in the ion milling step, thereby preventing both end portions C of the free magnetic layer26formed being damaged by ion milling, as compared with a conventional method.

In the embodiment shown inFIG. 5, both end portions27bof the backed layer27are partially left on both sides C of the free magnetic layer26, and the ferromagnetic layers28are respectively formed on both end portions27b. Namely, inFIG. 5, both end portions27bof the backed layer27are interposed between both end portions C of the free magnetic layer26and the ferromagnetic layers28. However, both end portions27bof the backed layer27are preferably formed to a thickness of as small as 0.2 Å to 3 Å. The thickness “0.2 Å” is the average over the whole of both end portions27bof the backed layer27. The thickness of 0.2 Å is smaller than the thickness of an atomic layer, and at both end portions27b, a portion having the constituent atoms of the backed layer27and a portion without the constituent atoms are thus islanded. Therefore, the thickness “0.2 Å” is the average over the whole of both end portions27bof the backed layer27.

As described above, each of both end portions27bof the backed layer27is formed to a thickness of as small as 0.2 Å to 3 Å, so that ferromagnetic coupling occurs between both end portions C of the free magnetic layer26and the ferromagnetic layers28. The ferromagnetic layers28are strongly put into a single magnetic domain state in the track width direction (the X direction) by exchange coupling magnetic fields produced between the ferromagnetic layers28and the second antiferromagnetic layers29respectively formed thereon. As a result, both end portions C of the free magnetic layer26on which ferromagnetic coupling with the ferromagnetic layers28is exerted are also oriented in the same direction as the magnetization direction of the ferromagnetic layers28, and strongly put into a single magnetic domain state in the track width direction (the X direction).

The term “ferromagnetic coupling” represents that magnetization of each of both end portions C of the free magnetic layer26is oriented in the same direction as the magnetization direction of the ferromagnetic layers28by RKKY ferromagnetic coupling between both end portions C of the free magnetic layer26and the ferromagnetic layers28through both end portions27bof the backed layer27, or a direct exchange interaction through defects such as pin holes or the like, which are formed in both end portions27bof the backed layer27.

The constituent element of both end portions27bof the backed layer27thermally diffuses by annealing in a magnetic field for producing exchange coupling magnetic fields between the ferromagnetic layers28and the second antiferromagnetic layers29. For example, when each of the ferromagnetic layers28and the free magnetic layer26comprises a NiFe alloy, and the backed layer27comprises Cu, and particularly, when both end portions27bof the backed layer27are formed to a very small thickness, both end portions27bof the backed layer27disappear by the thermal diffusion, and a NiFeCu alloy layer is formed on each of the backed layer side surfaces of the free magnetic layer26and the ferromagnetic layers28. Therefore, both end portions C of the free magnetic layer26and the ferromagnetic layers28function as an integrated ferromagnetic layer.

Therefore, when the magnetizations of the ferromagnetic layers28are pinned in the track width direction (the X direction) by the exchange coupling magnetic fields produced between the ferromagnetic layers28and the antiferromagnetic layers29, both end portions C of the free magnetic layer26are oriented in the same direction as the magnetization direction of the ferromagnetic layers28, and strongly put into the single magnetic domain state in the track width direction (the X direction).

In the present invention, each of the ferromagnetic layers28is preferably formed to a thickness of 2 Å to 50 Å.

In the present invention, even when the ferromagnetic layers28are thinly formed, the ferromagnetic coupling can be effectively produced between the ferromagnetic layers28and both end portions C of the free magnetic layer26. This is because both end portions C of the free magnetic layer26maintain the proper magnetic properties without being affected by ion milling. When each of the ferromagnetic layers28is formed to the above-described small thickness, large exchange coupling magnetic fields can be produced between the ferromagnetic layers28and the second antiferromagnetic layers29. Furthermore, it is possible to appropriately suppress a problem in which an excessive static magnetic field from the inner side of each of the ferromagnetic layers28affects the central portion D of the free magnetic layer26, deteriorating the sensitivity of the free magnetic layer26.

As described above, in the embodiment shown inFIG. 5, the magnetization of each of both end portions C of the free magnetic layer26is appropriately fixed in the track width direction (the X direction).

On the other hand, the magnetization of the central portion D of the free magnetic layer26is weakly put into the single magnetic domain state in a level permitting reversal of magnetization. The width dimension of the central portion D in the track width direction (the X direction) substantially coincides with the track width Tw defined by the distance between the lower surfaces of the ferromagnetic layers28in the track width direction (the X direction). Therefore, even when narrowing of the track progresses with increases in the recording density, the region of the track width Tw can be properly defined as a sensitive region permitting reversal of magnetization, and the magnetic sensing element having the specular layer31and capable of appropriately complying with a higher recording density can be manufactured. The track width is preferably 0.2 μm or less.

InFIG. 5, the material of the specular layer31is an oxide or nitride comprising at least one of Cr, Mo, W, Ti, Si, Ge, and Al. However, the material of the specular layer31is not limited to this as long as the specular layer31made of a material other than the above material can protect the backed layer27and the free magnetic layer26from oxidization by air exposure even when the thickness is in the range of 3 Å to 15 Å.

The thicknesses and the materials of the layers not described above with reference toFIG. 5are the same asFIG. 1(refer to FIG.1).

FIG. 6is a partial sectional view of the structure of a magnetic sensing element according to a sixth embodiment of the present invention, as viewed from the side facing a recording medium.

The embodiment shown inFIG. 6is the same as the embodiment shown inFIG. 5except that the form of a backed layer27is different from FIG.5. Therefore, the form of the backed layer27is mainly described below.

InFIG. 6, the backed layer27is formed only on the central portion D of the free magnetic layer26, without being formed on both end portions C of the free magnetic layer26. As described above with reference toFIG. 5, the total thickness h3of the backed layer27and the specular layer31formed on the free magnetic layer26is 5 Å to 20 Å.

Therefore, in the present invention, in the step of removing the backed layer27and the specular layer31from both end portions C of the free magnetic layer26, only the backed layer27and the specular layer31can be appropriately removed even by low-energy ion milling.

Namely, in the present invention, low-energy ion milling is used, and thus the milling rate can be decreased as compared with high-energy milling to permit removal of only the backed layer27and the specular layer31. Therefore, milling can be properly controlled to minimize damage to both end portions C of the free magnetic layer26by ion milling.

Therefore, in the embodiment shown inFIG. 6, both end portions C of the free magnetic layer26are less damaged by ion milling, and thus the magnetic properties of both end portions C of the free magnetic layer26can be maintained in a good state. Furthermore, the ferromagnetic layers28and the second antiferromagnetic layers29are formed on both end portions C of the free magnetic layer26, and the magnetizations of the ferromagnetic layers28are strongly pinned in the track width direction by exchange coupling magnetic fields between the ferromagnetic layers28and the antiferromagnetic layers29. As a result, the magnetizations of both end portions C of the free magnetic layer26ferromagnetically coupled with the ferromagnetic layers28can be strongly put into the single magnetic domain state in the track width direction.

Therefore, in the present invention, even with a narrower track, the magnetization of the free magnetic layer26can be effectively controlled, and the magnetic sensing element having the specular layer31and excellent for a higher recording density can be manufactured.

In the embodiment shown inFIG. 6, the materials and the thicknesses of the other layers are the same as the embodiment shown inFIG. 5except that the form of the backed layer27is different. Thus, a detailed description of the other layers is omitted (refer to FIGS.1and5).

FIG. 7is a partial sectional view of the structure of a magnetic sensing element according to a seventh embodiment of the present invention, as viewed from the side facing a recording medium.

The embodiment shown inFIG. 7is different from the embodiments shown inFIGS. 5 and 6in that the backed layer27is not formed on the free magnetic layer26. InFIG. 7, only the specular layer31is formed on the free magnetic layer26.

In the embodiment shown inFIG. 7, the thickness of the central portion31aof the specular layer31is larger than that of both end portions31b.

As described above with reference toFIG. 5, the specular layer31is preferably made of an oxide or nitride comprising at least one of Cr, Mo, W, Ti, Si, Ge, and Al.

The thickness of the central portion31aof the specular layer31is preferably 3 Å to 15 Å.

In the present invention, the specular layer31comprising the above material can be provided with the specular effect, and even with a thickness of as small as 3 Å to 15 Å, the specular layer31can be caused to function as the anti-oxidization layer.

In this embodiment, only the specular layer31having a thickness of as small as 3 Å to 15 Å is formed on the free magnetic layer26, and thus the specular layer31can be removed from both end portions C of the free magnetic layer26by using low-energy ion milling in the ion milling step. Thus, the ion milling can easily be controlled to stop at a predetermined position.

In the embodiment shown inFIG. 7, both end portions31bof the specular layer31are left on both end portions C of the free magnetic layer26. However, the thickness of each of both end portions31bof the specular layer is as small as 0.2 Å (the average over the whole of both end portions31b) to 3 Å. When such thin ends31bof the specular layer31are left, ferromagnetic coupling can be property produced between both end portions C of the free magnetic layer26and the ferromagnetic layers28, both end portions C respectively facing the ferromagnetic layers28with both end portions31bof the specular layer31provided therebetween. Alternatively, both end portions C of the free magnetic layer26and the ferromagnetic layers28can be combined to function as an integrated ferromagnetic layer by thermal diffusion, and both end portions C of the free magnetic layer26can be effectively put into the single magnetic domain state in the track width direction (the X direction).

On the other hand, the central portion D of the free magnetic layer26is weakly put into the single magnetic domain state in a level permitting reversal of magnetization with an external magnetic field.

In the embodiment shown inFIG. 7, it is possible to manufacture the magnetic sensing element having the specular layer31and capable of effectively controlling the magnetization of the free magnetic layer26even when the track is narrowed in future.

When the specular layer31can be appropriately provided with the function as the anti-oxidization layer even if the thickness of the central portion31aof the specular layer31formed on the central portion D of the free magnetic layer26is as small as 3 Å or less, the thickness of the central portion31amay be 3 Å or less. In this case, the central portion31aof the specular layer31may be the same as the thicknesses of both end portions31b.

The thicknesses and the material of the layers are not described with reference toFIG. 7, but are described above with reference toFIGS. 1 and 5(refer to FIGS.1and5).

FIG. 8is a partial sectional view of the structure of a magnetic sensing element according to an eighth embodiment of the present invention, as viewed from the side facing a recording medium.

In the embodiment shown inFIG. 8, the forms of layers are the same as the embodiment shown inFIG. 7except the specular layer31. Therefore, the specular layer31is mainly described below.

InFIG. 8, the specular layer31is formed only on the central portion D of the free magnetic layer26, without being formed on both end portions C of the free magnetic layer26. As described above with reference toFIG. 7, the thickness of the specular layer31formed on the central portion D of the free magnetic layer26is 3 Å to 15 Å.

Therefore, in the present invention, the specular layer31can be appropriately removed from both end portions C of the free magnetic layer26even by using low-energy ion milling in the ion milling step.

Namely, in the present invention, low-energy ion milling is used, and thus the milling rate can be decreased as compared with high-energy milling to permit removal of only the specular layer31. Therefore, milling can properly be controlled to minimize damage to both end portions C of the free magnetic layer26by ion milling.

Therefore, in the embodiment shown inFIG. 8, both end portions C of the free magnetic layer26are less damaged by ion milling, and thus the magnetic properties of both end portions C of the free magnetic layer26can be maintained in a good state. Furthermore, the ferromagnetic layers28and the second antiferromagnetic layers29are formed on both end portions C of the free magnetic layer26, and the magnetizations of the ferromagnetic layers28are strongly pinned in the track width direction by exchange coupling magnetic fields between the ferromagnetic layers28and the antiferromagnetic layers29. As a result, the magnetizations of both end portions C of the free magnetic layer26ferromagnetically coupled with the ferromagnetic layers28can be strongly put into the single magnetic domain state in the track width direction.

Therefore, in the present invention, even with a narrower track, magnetization of the free magnetic layer26can be effectively controlled, and the magnetic sensing element having the specular layer31and excellent for a higher recording density can be manufactured.

In the embodiment shown inFIG. 8, the materials and the thicknesses of the other layers are the same as the embodiment shown inFIG. 7except that the form of the specular layer31is different. Thus, a detailed description of the other layers is omitted (refer to FIGS.1and5).

Next, the form of the free magnetic layer26will be described below.

In each of the magnetic sensing elements shown inFIGS. 1to8, the free magnetic layer26has a two-layer structure comprising an anti-diffusion layer26amade of CoFe or Co and provided in contact with the nonmagnetic material layer25, and a magnetic material layer26bcomprising a magnetic material such as a NiFe alloy or the like.

The free magnetic layer26may comprise a single layer of a magnetic material. As the magnetic material, a NiFe alloy, a CoFe alloy, a CoFeNi alloy, Co, a CoNi alloy, or the like can be selected. Particularly, the free magnetic layer26preferably comprises a CoFeNi alloy.

FIG. 9is an enlarged partial sectional view mainly showing the free magnetic layer26, as viewed from the side facing a recording medium.

In the form shown inFIG. 9, the free magnetic layer26has a three-layer structure. All layers36,37and38constituting the free magnetic layer26are magnetic material layers, the magnetic material layer36being an anti-diffusion layer for preventing diffusion of elements to the nonmagnetic material layer25. The magnetic material layer36is made of CoFe, Co, or the like.

In the embodiments shown inFIGS. 1 and 5, the backed layer27is formed on both end portions of the magnetic material layer38. In the embodiments shown inFIGS. 3 and 7, the specular layer31is formed on both end portions of the magnetic material layer38. In this case, the magnetic material layer38preferably comprises a CoFe alloy so that RKKY ferromagnetic coupling between the ferromagnetic layers28and the nonmagnetic layer38with the backed layer27provide therebetween can be increased.

An example of a combination of materials for the three layers shown inFIG. 9is a combination of the magnetic material layer36: CoFe/the magnetic material layer37: NiFe/the magnetic material layer38: CoFe.

The thickness of the free magnetic layer26comprising only a magnetic material is preferably about 30 Å to 40 Å. The composition of the CoFe alloy used for the free magnetic layer26comprises, for example, 90 at % of Co and 10 at % of Fe.

FIG. 10is an enlarged partial sectional view showing another form of the free magnetic layer26. The structure of the free magnetic layer26shown inFIG. 10is referred to as a “laminated ferrimagnetic structure”. This permits a decrease in the effective magnetic thickness of the free magnetic layer26without excessively decreasing the physical thickness of the free magnetic layer26, thereby improving sensitivity to an external magnetic field.

InFIG. 10, reference numeral39and41each denote a magnetic layer, and reference numeral40denotes a nonmagnetic intermediate layer. Each of the magnetic layers39and41comprises a magnetic material such as a NiFe alloy, a CoFe alloy, a CoFeNi alloy, Co, a CoNi alloy, or the like. Particularly, the magnetic layer39and/or the magnetic layer41preferably comprises a CoFeNi alloy. The composition preferably comprises 9 at % to 17 at % of Fe, 0.5 at % to 10 at % of Ni, and the balance of Co.

Consequently, a coupling magnetic field due to a RKKY interaction between the magnetic layers39and41can be increased. Specifically, a spin-flop magnetic field (Hsp) can be increased to about 293 (kA/m) or more. Therefore, magnetizations of the magnetic layers39and41can be appropriately put into an antiparallel state. Within the above composition range, the magneto-striction of the free magnetic layer26can be maintained in the range of −3×10−6to 3×10−6, and coercive force can be decreased to 790 (A/m) or less.

Furthermore, it is possible to properly improve the soft magnetic characteristics of the free magnetic layer26, and suppress decreases in the amount (ΔR) and the rate (ΔR/R) of change in resistance due to Ni diffusion to the nonmagnetic material layer25.

The nonmagnetic intermediate layer40preferably comprises at least one of Ru, Rh, Ir, Cr, Re and Cu.

For example, the thickness of the magnetic layer39is about 35 Å, the thickness of the nonmagnetic layer40is about 9 Å, and the thickness of the magnetic layer41is about 15 Å.

Also, the anti-diffusion layer comprising a CoFe alloy or Co may be formed between the magnetic layer39and the nonmagnetic material layer25. Furthermore, a magnetic layer comprising a CoFe alloy may be formed on the magnetic layer41.

In this case, with the magnetic layer39and/or the magnetic layer41comprising a CoFeNi alloy, the composition of the CoFeNi alloy preferably comprises 7 at % to 15 at % of Fe, 5 at % to 15 at % of Ni, and the balance of Co.

Consequently, a coupling magnetic field due to a RKKY interaction between the magnetic layers39and41can be increased. Specifically, a spin-flop magnetic field (Hsp) can be increased to about 293 (kA/m) or more. Therefore, magnetizations of the magnetic layers39and41can be appropriately put into an antiparallel state.

Within the above composition range, the magneto-striction of the free magnetic layer26can be maintained in the range of −3×10−6to 3×10−6, and the coercive force can be decreased to 790 (A/m) or less. Furthermore, the soft magnetic characteristics of the free magnetic layer26can be improved.

FIGS. 11to13are drawings respectively showing steps of a method of manufacturing the magnetic sensing element shown in FIG.1. Each ofFIGS. 11to13is a partial sectional view taken along the side facing the recording medium.

In the step shown inFIG. 11, the seed layer21comprising a NiFe alloy, a NiFeCr alloy or Cr is formed on the substrate20.

Then, the first antiferromagnetic layer23, the pinned magnetic layer24, the nonmagnetic material layer25, the free magnetic layer26, the backed layer27, and the specular layer31are continuously deposited on the seed layer21. Deposition of these layers is performed by a sputtering or vapor deposition method. The pinned magnetic layer24shown inFIG. 11has a laminated ferrimagnetic structure comprising the magnetic layers24aand24ceach comprising, for example, a CoFe alloy, and the nonmagnetic intermediate layer24bof Ru interposed between both magnetic layers24aand24c. The free magnetic layer26has a laminated structure comprising the antiferromagnetic layer26acomprising a CoFe alloy, and the magnetic material layer26bcomprising a NiFe alloy.

In the present invention, the first antiferromagnetic layer23is preferably made of a PtMn alloy, a X—Mn (wherein X is at least one element of Pd, Ir, Rh, Ru, Os, Ni, and Fe) alloy, or a Pt—Mn—X′ (wherein X′ is at least one element of Pd, Ir, Rh, Ru, Au, Ag, Os, Cr, Ni, Ar, Ne, Xe and Kr) alloy.

In the PtMn alloy and the alloy represented by the formula X—Mn, Pt or X is preferably in the range of 37 to 63 at %, and more preferably in the range of 47 to 57 at %. The upper and lower limits of these ranges represent “not more than” and “not less than”, respectively, unless otherwise specified.

In the alloy represented by the formula Pt—Mn—X′, X′+Pt is preferably in the range of 37 to 63 at %, and more preferably in the range of 47 to 57 at %. In the alloy represented by the formula Pt—Mn—X′, X′ is preferably in the range of 0.2 to 10 at %. However, when X′ is at least one of Pd, Ir, Rh, Ru, Os, Ni and Fe, X′ is preferably in the range of 0.2 to 40 at %.

In the present invention, the first antiferromagnetic layer23is preferably formed to a thickness of 80 Å to 300 Å. By forming such a thick first antiferromagnetic layer23, a large exchange coupling magnetic field can be produced between the first antiferromagnetic layer23and the pinned magnetic layer24by annealing in a magnetic field. Specifically, an exchange coupling magnetic field of 48 kA/m or more, for example, over 64 kA/m, can be produced.

In the step shown inFIG. 11, the backed layer27is preferably formed to a thickness of 2 Å to 5 Å. By forming the backed layer27having such a thickness, the spin filter effect can be appropriately exhibited. With the backed layer27having a thickness of over this range, the total thickness h1of the layers formed on the free magnetic layer26easily increases to 20 Å or more, and thus both end portions C of the free magnetic layer26are easily damaged by ion milling in the next ion milling step. Also, the backed layer27is preferably made of Cu, Ag, Au, Ru, or the like.

In the step shown inFIG. 11, the specular layer31is preferably formed by using an oxide or nitride comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements.

The method of forming the specular layer31will be described in detail below. In the present invention, first, an element film comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements is preferably formed to a thickness of as small as 1 Å to 5 Å on the backed layer27by sputtering or vapor deposition. The manufacturing method of the present invention is characterized in that the element film of the specular layer31is deposited to a very small thickness.

With the element film of less than 1 Å, oxidization of the element film influences the backed layer27and the free magnetic layer26, or the specular layer31undesirably cannot exhibit the effective specular effect.

With the element film of over 5 Å, oxidization of the element film produces the specular layer31having a thickness of as large as 10 Å or more. Particularly, in the step shown inFIG. 11, not only the specular layer31but also the backed layer27and the nonmagnetic layer32described below are formed on the free magnetic layer26, thereby increasing the total thickness h1of the layers formed on the free magnetic layer26to over 20 Å. Therefore, both end portions C of the free magnetic layer26are undesirably easily damaged by ion milling in the next ion milling step.

After the element film comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements is formed to a thickness of as small as 1 Å to 5 Å on the backed layer27, the element film is oxidized or nitrided at low pressure in the vacuum container.

The element film can be slowly oxidized or nitrided by low-pressure oxidization or nitriding in the vacuum container. Therefore, even when the element film has a thickness of as small as 1 Å to 5 Å, the element film can be appropriately oxidized or nitrided while properly preventing oxidization or nitriding of the backed layer27and the free magnetic layer26.

The oxidization is preferably natural oxidization, radical oxidization or plasma oxidization at low pressure.

In the present invention, the gas pressure in the vacuum container is preferably 0.13 Pa to 1.3×104Pa.

In the oxidization or nitriding step, the element film is oxidized or nitrided to form the specular layer31having a larger thickness than that of the element film in the deposition step. However, as described above, the element film has a very small thickness of 1 Å to 5 Å in the deposition step, and thus the thickness of the specular layer31formed by oxidization or nitriding is 3 Å to 10 Å, thereby maintaining the specular layer31very thin.

In the present invention, after the specular layer31is formed in the vacuum container, the nonmagnetic layer32shown inFIG. 11is formed on the specular layer31by sputtering or vapor deposition in the vacuum container with the magnetic sensing element being held in the vacuum container during manufacture. By depositing the nonmagnetic layer32in the vacuum container, the specular layer31is not exposed to the air, and thus the specular layer31, the backed layer27and the free magnetic layer26can be appropriately protected from oxidization by air exposure before the nonmagnetic layer32is formed.

In the present invention, the nonmagnetic layer32is preferably made of at least one of Ru, Rh, Pd, Ir, Os, Re, Cr, Cu, Pt, and Au.

The nonmagnetic layer32made of the above element comprises a dense film hard to oxidize, and thus functions as the anti-oxidization layer even with a small thickness.

In the present invention, the nonmagnetic layer32is preferably formed to a small thickness of 2 Å to 8 Å. With the nonmagnetic layer32having a thickness of less than 2 Å, the function as the anti-oxidization layer deteriorates, thereby making the specular layer31, the backed layer27and the free magnetic layer26formed below the specular layer31easy to oxidize.

On the other hand, with the nonmagnetic layer32having a thickness of 8 Å or more, the total thickness of the backed layer27, the specular layer31and the nonmagnetic layer32formed on the free magnetic layer26becomes over 20 Å. Therefore, in the next step of ion milling both end portions C of the free magnetic layer26, both end portions C of the free magnetic layer26are undesirably easily damaged by ion milling. When the specular layer31is formed by using an oxide or nitride comprising at least one of Cr, Mo, W, Ti, Si, Ge and Al, oxidation of the specular layer31less proceeds deeply even in the air. In this case, the specular layer31need not be formed in the vacuum container.

In the present invention, the thickness of each of the backed layer27, the specular layer31and the nonmagnetic layer32formed on the free magnetic layer26is preferably controlled so that the total thickness h1is 7 Å to 20 Å. With such a total thickness h1, each of the backed layer27, the specular layer31and the nonmagnetic layer32can appropriately exhibit its function, and damage of the ion milling to both end portions C of the free magnetic layer26in the next ion milling step can be decreased.

As shown inFIG. 11, after each of the layers up to the nonmagnetic layer32is deposited on the substrate20, first magnetic field annealing is performed. Namely, the layers are heat-treated at a first heat treatment temperature with a first magnetic field (the Y direction shown in the drawing) applied in a direction perpendicular to the track width Tw direction (the X direction shown in the drawing), to produce an exchange coupling magnetic field between the first antiferromagnetic layer23and the magnetic layer24aconstituting the pinned magnetic layer24, so that the magnetization of the magnetic layer24ais pinned in the Y direction shown in the drawing. The magnetization of the other magnetic layer24cis pinned in the direction opposite to the Y direction by exchange coupling due to a RKKY interaction with the magnetic layer24a. For example, the first heat treatment temperature is 270° C., and the magnitude of the magnetic field applied is 800 K (A/m).

In the step shown inFIG. 12, a resist layer49is formed on the upper surface of the nonmagnetic layer32, and then exposed to light and developed to leave the resist layer49having the shape shown inFIG. 12on the nonmagnetic layer32. The resist layer49is, for example, a lift-off resist layer.

Next, both end portions32bof the nonmagnetic layer32, which are not covered with the resist layer49, are removed by ion milling from the direction of arrow H shown inFIG. 12(removing the portions of the nonmagnetic layer32as shown by dotted lines in FIG.12).

Furthermore, after both end portions32bof the nonmagnetic layer32are completely removed, both end portions31bof the specular layer31formed below the nonmagnetic layer32are completely removed. Furthermore, both end portions27bof the backed layer27, which are exposed, are partially removed (leaving the portions of the specular layer31and the backed layer27, as shown by dotted lines in FIG.12).

In the step shown inFIG. 12, both end portions27bof the backed layer27are thinly left on both end portions C of the free magnetic layer26.

As described above, the total thickness h1of the backed layer27, the specular layer31and the nonmagnetic layer32formed on the free magnetic layer26is 20 Å or less. In the present invention, therefore, low-energy ion milling can be used in the ion milling step shown in FIG.12. Since such low-energy ion milling can be used, ion milling can easily be controlled to stop at an intermediate position of both end portions27bof the backed layer27.

In this way, in the present invention, low-energy ion milling can be used, and thus controllability of the depth of milling can be improved, as compared with a conventional milling method.

However, when the backed layer27is formed to a small thickness of 3 Å or less, ion milling may be stopped at the moment when the surfaces of both end portions27bof the backed layer27are exposed. In this case, the central portion27aof the backed layer27can be formed to the same thickness as both end portions27b.

The ion milling is preferably performed for a milling time of about 30 seconds to 60 seconds at a milling angle of 30° to 70°, preferably 40° to 60°, with respect to the direction perpendicular to the surface of the substrate20. As a result, the backed layer27can be thinly left on both end portions C of the free magnetic layer26.

In the present invention, the thickness of each of both end portions27bof the backed layer27, which are left on both end portions C of the free magnetic layer26, is preferably 0.2 Å to 3 Å. In the next step, the ferromagnetic layers28are formed on both end portions27bof the backed layer27. However, when both end portions27bof the backed layer27are thick, both end portions C of the free magnetic layer26are magnetically separated from the ferromagnetic layers28, thereby failing to appropriately control the magnetization of each of both end portions C of the free magnetic layer26.

In the present invention, both end portions27bof the backed layer27are left in a thickness of 0.2 Å to 3 Å, and thus ferromagnetic coupling can be produced between both end portions C of the free magnetic layer26and the ferromagnetic layers28, thereby permitting proper control of the magnetization of the free magnetic layer26.

The term “ferromagnetic coupling” represents that each of both end portions C of the free magnetic layer26is magnetized in the same direction as the magnetization direction of the ferromagnetic layers28by RKKY ferromagnetic coupling between both end portions C of the free magnetic layer26and the ferromagnetic layers28through both end portions27bof the backed layer27, or a direct exchange interaction between both end portions C of the free magnetic layer26and the ferromagnetic layers28through defects such as pinholes or the like, which are formed in the backed layer27.

Next, the step shown inFIG. 13is performed. In the step shown inFIG. 13, the ferromagnetic layers28, the second antiferromagnetic layers29, and the electrode layers30are continuously deposited on both end portions27bof the backed layer27. These layers can be deposited by sputtering or vapor deposition. The upper surfaces28aof the deposited ferromagnetic layers28, the upper surfaces29aof the deposited second antiferromagnetic layers29, and the upper surfaces30aof the deposited electrode layers30are inclined or curved surfaces so that the distance between both surfaces gradually increases in the direction (the Z direction shown in the drawing) from the lower side to the upper side.

In this embodiment, the track width Tw is defined by the distance between the lower surfaces of the ferromagnetic layers28.

The material used for the second antiferromagnetic layers29is preferably the same as that used for the first antiferromagnetic layer23.

Each of the second antiferromagnetic layers29is preferably formed to a thickness of as large as about 80 Å to 500 Å. This is because an exchange coupling magnetic field of appropriate magnitude can be produced between the second antiferromagnetic layers29and the ferromagnetic layers28.

After the layers up to the electrode layers30are deposited as shown inFIG. 13, the resist layer49to which a ferromagnetic material layer28bcomprising the constituent elements of the ferromagnetic layers28, an antiferromagnetic material layer29bcomprising the constituent elements of the second antiferromagnetic layers29, and an electrode material layer30bcomprising the constituent elements of the electrode layers30are adhered is removed by liftoff.

Next, second magnetic field annealing is performed. In this annealing, the magnetic field direction coincides with the track width direction (the X direction shown in the drawing). In the second magnetic field annealing, a second applied magnetic field is lower than the exchange anisotropic magnetic field of the first antiferromagnetic layer23, and the heat treatment temperature is lower than the blocking temperature of the first antiferromagnetic layer23. Consequently, the exchange anisotropic magnetic field of the second antiferromagnetic layers29can be oriented in the track width direction (the X direction) while the exchange anisotropic magnetic field of the first antiferromagnetic layer23is oriented in the height direction (the Y direction). For example, the second heat treatment temperature is 250° C., and the magnitude of the magnetic field applied is 24 k (A/m).

As shown inFIG. 13, after the second antiferromagnetic layers29are formed on the ferromagnetic layers28, the second magnetic field annealing is performed to produce the exchange coupling magnetic field between the ferromagnetic layers28and the second antiferromagnetic layers29, so that magnetization of the ferromagnetic layers28is pinned in the track width direction (the X direction shown in the drawing). As a result, magnetization of each of both end portions C of the free magnetic layer26is pinned in the same direction as the magnetization direction of the ferromagnetic layers28by ferromagnetic coupling with the ferromagnetic layers28through both end portions27bof the backed layer27.

Alternatively, the constituent elements of both end portions27bof the backed layer27thermally diffuse to the ferromagnetic layers28and both end portions C of the free magnetic layer26in the second magnetic field annealing, so that both end portions C of the free magnetic layer26and the ferromagnetic layers28can be caused to function as an integrated ferromagnetic layer, and thus both end portions C of the free magnetic layer26can be appropriately pinned in the track width direction.

The amount of the constituent elements of the backed layer27, which diffuse to the surface of the free magnetic layer26, is larger than to the bottom of the free magnetic layer26. Conversely, the amount the constituent elements of the backed layer27, which diffuse to the bottoms of the ferromagnetic layers28, is larger than to the surfaces of the ferromagnetic layers28. The ratio of the diffusing constituent elements of the backed layer27decreases from the surface to the bottom of the free magnetic layer26, while the ratio of the diffusing constituent elements of the backed layer27decreases from the bottoms to the surfaces of the ferromagnetic layers28. These changes in composition can be recognized by a SIMS analyzer (secondary ion mass spectrometer).

On the other hand, the ferromagnetic layers28and the second antiferromagnetic layers29are provided on only both end portions C of the free magnetic layer26without being provided on the central portion D of the free magnetic layer26, and thus magnetization of the central portion D of the free magnetic layer26is not strongly pinned. The magnetization of the central portion D of the free magnetic layer26is put into the single magnetic domain state in the track width direction (the X direction) in a level permitting reversal of magnetization with an external magnetic field.

In the step shown inFIG. 13, each of the ferromagnetic layers28is preferably formed to a thickness of 2 Å to 50 Å.

In the present invention, both end portions C of the free magnetic layer26are not damaged by ion milling in the step shown inFIG. 12, and thus maintain the good magnetic characteristics. Therefore, even when the ferromagnetic layers28are formed to the above small thickness, ferromagnetic coupling with the ferromagnetic layers28can be increased. In the present invention, therefore, unlike a conventional element, the ferromagnetic layers28need not be formed to a large thickness, and thus the exchange coupling magnetic field produced between the ferromagnetic layers28and the second antiferromagnetic layers29can be sufficiently increased. At the same time, the influence of an excessive static magnetic field from the inner end28aof each of the ferromagnetic layers28on the central portion D of the free magnetic layer26can be suppressed, thereby permitting the manufacture of the magnetic sensing element having excellent sensitivity even with a higher recording density.

As described above, the manufacturing method of the present invention can manufacture the magnetic sensing element permitting proper control of the magnetization of the free magnetic layer26, and having the specular layer31having excellent reproduction sensitivity even with a narrower track, as compared with a conventional sensing element.

The magnetic sensing element shown inFIG. 1can be manufactured by the above-described manufacturing method. In the method of manufacturing the magnetic sensing element shown inFIG. 2, both end portions32bof the nonmagnetic layer32, both end portions31bof the specular layer31and both end portions27bof the backed layer27, all of which are positioned on both sides of the resist layer49in the track width direction (the X direction), are removed to expose both end portions C of the free magnetic layer26in the step shown in FIG.12.

In the present invention, the total thickness h1of the backed layer27, the specular layer31and the nonmagnetic layer32formed on the free magnetic layer26in the step shown inFIG. 11is 20 Å or less. Therefore, in the step shown inFIG. 12, all of both end portions32bof the nonmagnetic layer32, both end portions31bof the specular layer31and both end portions27bof the backed layer27can be removed by low-energy ion milling, and milling can easily be controlled to stop at the moment when both end portions27bof the backed layer27are completely removed. In the present invention, therefore, even when both end portions C of the free magnetic layer26are exposed in the step shown inFIG. 12, both end portions C of the free magnetic layer26are less damaged by ion milling, thereby maintaining the magnetic characteristics of both end portions C of the free magnetic layer26in a good state. Thus, magnetization of the free magnetic layer26can be appropriately controlled.

In the method of manufacturing the magnetic sensing element shown inFIG. 3, the specular layer31and the nonmagnetic layer32are formed on the free magnetic layer26in the step shown inFIG. 11, and then both end portions32bof the nonmagnetic layer32, which are exposed from both sides of the resist layer49in the track width direction (the X direction), are completely removed in the step shown in FIG.12. Furthermore, both end portions31bof the specular layer31, which are exposed from both sides, are partially removed to thinly (for example, 0.2 Å to 3 Å) leave both end portions31bof the specular layer31on both end portions C of the free magnetic layer26. Alternatively, when the specular layer31has a thickness of 3 Å or less, ion milling can be stopped not to further move the specular layer31at the moment when both end portions31bare exposed. Then, the step shown inFIG. 13may be performed.

In the method of manufacturing the magnetic sensing element shown inFIG. 4, the specular layer31and the nonmagnetic layer32are formed on the free magnetic layer26in the step shown in FIG.11. Then, in the step shown inFIG. 12, both end portions32bof the nonmagnetic layer32and both end portions31bof the specular layer31, which are exposed from both sides of the resist layer49in the track width direction (the X direction), are completely removed to expose the surfaces of both end portions C of the free magnetic layer26. Then, the step shown inFIG. 13may be performed.

FIGS. 14to16are drawings respectively showing steps of a method of manufacturing the magnetic sensing element shown in FIG.5. Each ofFIGS. 11to13is a partial sectional view taken along the side facing the recording medium.

In the step shown inFIG. 14, the seed layer21comprising a NiFe alloy, a NiFeCr alloy or Cr is formed on the substrate20.

Then, the first antiferromagnetic layer23, the pinned magnetic layer24, the nonmagnetic material layer25, the free magnetic layer26, the backed layer27, and the specular layer31are continuously deposited on the seed layer21. Deposition of these layers is performed by a sputtering or vapor deposition method. The pinned magnetic layer24shown inFIG. 14has a laminated ferrimagnetic structure comprising the magnetic layers24aand24ceach comprising, for example, a CoFe alloy, and the nonmagnetic intermediate layer24bof Ru interposed between both magnetic layers24aand24c. The free magnetic layer26has a laminated structure comprising the antiferromagnetic layer26acomprising a CoFe alloy, and the magnetic material layer26bcomprising a NiFe alloy.

In the present invention, the first antiferromagnetic layer23is preferably made of a PtMn alloy, a X—Mn (wherein X is at least one element of Pd, Ir, Rh, Ru, Os, Ni, and Fe) alloy, or a Pt—Mn—X′ (wherein X′ is at least one element of Pd, Ir, Rh, Ru, Au, Ag, Os, Cr, Ni, Ar, Ne, Xe and Kr) alloy.

In the PtMn alloy and the alloy represented by the formula X—Mn, Pt or X is preferably in the range of 37 to 63 at %, and more preferably in the range of 47 to 57 at %. The upper and lower limits of these ranges represent “not more than” and “not less than”, respectively, unless otherwise specified.

In the alloy represented by the formula Pt—Mn—X′, X′+Pt is preferably in the range of 37 to 63 at %, and more preferably in the range of 47 to 57 at %. In the alloy represented by the formula Pt—Mn—X′, X′ is preferably in the range of 0.2 to 10 at %. However, when X′ is at least one of Pd, Ir, Rh, Ru, Os, Ni and Fe, X′ is preferably in the range of 0.2 to 40 at %.

In the present invention, the first antiferromagnetic layer23is preferably formed to a thickness of 80 Å to 300 Å. By forming such a thick first antiferromagnetic layer23, a large exchange coupling magnetic field can be produced between the first antiferromagnetic layer23and the pinned magnetic layer24by annealing in a magnetic field. Specifically, an exchange coupling magnetic field of 48 kA/m or more, for example, over 64 kA/m, can be produced.

In the step shown inFIG. 14, the backed layer27is preferably formed to a thickness of 2 Å to 5 Å. By forming the backed layer27having a thickness within this range, the spin filter effect can be appropriately exhibited. With the backed layer27having a thickness of over this range, the total thickness h3of the layers formed on the free magnetic layer26easily increases to 20 Å or more, and thus both end portions C of the free magnetic layer26are easily damaged by ion milling in the next ion milling step. Also, the backed layer27is preferably made of Cu, Ag, Au, Ru, or the like.

In the step shown inFIG. 14, the specular layer31is preferably formed by using an oxide or nitride comprising at least one of Cr, Mo, W, Ti, Si, Ge, and Al.

The material for the specular layer31used in the step shown inFIG. 14is more limited than the material for the specular layer31used in the step shown in FIG.11. The reason for this that the nonmagnetic layer32is not formed on the specular layer31in the step shown inFIG. 14, and thus the specular layer31itself must be provided with the function as the anti-oxidization layer.

The specular layer31comprising at least one element selected from Cr, Mo, W, Ti, Si, Ge, and Al has a low rate of oxidization by air exposure in the depth direction. Therefore, even when an element film is thinly formed on the backed layer27, there is no problem in which oxidization reaches the backed layer27and the free magnetic layer26.

In the present invention, first, an element film comprising at least one of Cr, Mo, W, Ti, Si, Ge, and Al is formed to a thickness of as small as 1 Å to 7 Å on the backed layer27by sputtering or vapor deposition. With the element film having a thickness of less than this range, the function of the element film as the anti-oxidization layer deteriorates, and thus the backed layer27and the free magnetic layer26are undesirably easily oxidized by air exposure. With the element film having a thickness of over the range, oxidization of the element film produces the specular layer31having a excessively large. Therefore, both end portions C of the free magnetic layer26are undesirably easily damaged by ion milling in the next ion milling step.

Since the element film has a very low rate of oxidation by air exposure in the depth direction, as compared with a Ta film or the like, oxidization does not reach the backed layer27and the free magnetic layer26through the element film even when the element film formed on the backed layer27is exposed to the air. Therefore, the element film has the function as the appropriate anti-oxidization layer.

The element film is oxidized to form the specular layer31having a larger thickness than that of the element film in the deposition step. However, the element film has a very small thickness of 1 Å to 7 Å in the deposition step, and thus the specular layer31formed by oxidization has a small thickness. In the present invention, the thickness of the specular layer31is preferably 3 Å to 15 Å. This is because with the specular layer31having an excessively large thickness, both end portions C of the free magnetic layer26are undesirably easily damaged by ion milling in the next ion milling step.

The element film is preferably oxidized by natural oxidization, radial oxidation or plasma oxidization. The element film may be nitrided to form the specular layer31comprising a nitride.

In the present invention, the thickness of each of the backed layer27and the specular layer31formed on the free magnetic layer26is preferably controlled so that the total thickness h3is 5 Å to 20 Å. With such a total thickness h3, each of the backed layer27and the specular layer31can appropriately exhibit its function, and damage of the ion milling to both end portions C of the free magnetic layer26in the next ion milling step can be decreased.

As shown inFIG. 14, after each of the layers up to the specular layer31is deposited on the substrate20, first magnetic field annealing is performed. Namely, the layers are heat-treated at a first heat treatment temperature with a first magnetic field (the Y direction shown in the drawing) applied in a direction perpendicular to the track width Tw direction (the X direction shown in the drawing), to produce an exchange coupling magnetic field between the first antiferromagnetic layer23and the magnetic layer24aconstituting the pinned magnetic layer24, so that the magnetization of the magnetic layer24ais pinned in the Y direction shown in the drawing. The magnetization of the other magnetic layer24cis pinned in the direction opposite to the Y direction by exchange coupling due to a RKKY interaction with the magnetic layer24a. For example, the first heat treatment temperature is 270° C., and the magnitude of the magnetic field applied is 800 K (A/m).

In the step shown inFIG. 15, a resist layer50is formed on the upper surface of the specular layer31, and then exposed to light and developed to leave the resist layer50having the shape shown inFIG. 15on the specular layer31. The resist layer50is, for example, a lift-off resist layer.

Next, both end portions31bof the specular layer31, which are not covered with the resist layer50, are removed by ion milling from the direction of arrow I shown inFIG. 15(removing the portions of the specular layer31as shown by dotted lines in FIG.15).

Furthermore, after both end portions31bof the specular layer31are completely removed, both end portions27bof the backed layer27, which are exposed, are partially removed (leaving the portions of the specular layer31and the backed layer27, as shown by dotted lines in FIG.15).

In the step shown inFIG. 15, both end portions27bof the backed layer27are thinly left on both end portions C of the free magnetic layer26.

As described above, the total thickness h3of the backed layer27and the specular layer31formed on the free magnetic layer26is 20 Å or less. In the present invention, therefore, low-energy ion milling can be used in the ion milling step shown in FIG.15. Since such low-energy ion milling can be used, ion milling can easily be controlled to stop at an intermediate position of both end portions27bof the backed layer27.

In this way, in the present invention, low-energy ion milling can be used, and thus controllability of the depth of milling can be improved, as compared with a conventional milling method.

However, when the backed layer27is formed to a small thickness of 3 Å or less, ion milling may be stopped at the moment when the surfaces of both end portions27bof the backed layer27are exposed. In this case, the central portion27aof the backed layer27can be formed to the same thickness as both end portions27b.

The ion milling is preferably performed for a milling time of about 30 seconds to 60 seconds at a milling angle of 30° to 70°, preferably 40° to 60°, with respect to the direction perpendicular to the surface of the substrate20. As a result, both end portions27bof the backed layer27can be thinly left on both end portions C of the free magnetic layer26.

In the present invention, the thickness of each of both end portions27bof the backed layer27, which are left on both end portions C of the free magnetic layer26, is preferably 0.2 Å to 3 Å. In the next step, the ferromagnetic layers28are formed on both end portions27bof the backed layer27. However, when both end portions27bof the backed layer27are thick, both end portions C of the free magnetic layer26are magnetically separated from the ferromagnetic layers28, thereby failing to appropriately control magnetization of each of both end portions C of the free magnetic layer26.

In the present invention, both end portions27bof the backed layer27are left in a thickness of 0.2 Å to 3 Å, and thus ferromagnetic coupling can be produced between both end portions C of the free magnetic layer26and the ferromagnetic layers28, thereby permitting proper control of magnetization of the free magnetic layer26.

The term “ferromagnetic coupling” represents that each of both end portions C of the free magnetic layer26is magnetized in the same direction as the magnetization direction of the ferromagnetic layers28by RKKY ferromagnetic coupling between both end portions C of the free magnetic layer26and the ferromagnetic layers28through both end portions27bof the backed layer27, or a direct exchange interaction between both end portions C of the free magnetic layer26and the ferromagnetic layers28through defects such as pinholes or the like, which are formed in the backed layer27.

Next, the step shown inFIG. 16is performed. In the step shown inFIG. 16, the ferromagnetic layers28, the second antiferromagnetic layers29, and the electrode layers30are continuously deposited on both end portions27bof the backed layer27. These layers can be deposited by sputtering or vapor deposition. The upper surfaces28aof the deposited ferromagnetic layers28, the upper surfaces29aof the deposited second antiferromagnetic layers29, and the upper surfaces30aof the deposited electrode layers30are inclined or curved surfaces so that the distance between both surfaces gradually increases in the direction (the Z direction shown in the drawing) from the lower side to the upper side.

In this embodiment, the track width Tw is defined by the distance between the lower surfaces of the ferromagnetic layers28.

The material used for the second antiferromagnetic layers29is preferably the same as that used for the first antiferromagnetic layer23.

Each of the second antiferromagnetic layers29is preferably formed to a thickness of as large as about 80 Å to 500 Å. This is because an exchange coupling magnetic field of appropriate magnitude can be produced between the second antiferromagnetic layers29and the ferromagnetic layers28.

After the layers up to the electrode layers30are deposited as shown inFIG. 16, the resist layer50to which a ferromagnetic material layer28bcomprising the constituent elements of the ferromagnetic layers28, an antiferromagnetic material layer29bcomprising the constituent elements of the second antiferromagnetic layers29, and an electrode material layer30bcomprising the constituent elements of the electrode layers30are adhered is removed by liftoff.

Next, second magnetic field annealing is performed. In this annealing, the magnetic field direction coincides with the track width direction (the X direction shown in the drawing). In the second magnetic field annealing, the second applied magnetic field is lower than the exchange anisotropic magnetic field of the first antiferromagnetic layer23, and the heat treatment temperature is lower than the blocking temperature of the first antiferromagnetic layer23. Consequently, the exchange anisotropic magnetic field of the second antiferromagnetic layers29can be oriented in the track width direction (the X direction) while the exchange anisotropic magnetic field of the first antiferromagnetic layer23is oriented in the height direction (the Y direction). For example, the second heat treatment temperature is 250° C., and the magnitude of the magnetic field applied is 24 k (A/m).

As shown inFIG. 16, after the second antiferromagnetic layers29are formed on the ferromagnetic layers28, the second magnetic field annealing is performed to produce the exchange coupling magnetic fields between the ferromagnetic layers28and the second antiferromagnetic layers29, so that the magnetizations of the ferromagnetic layers28are pinned in the track width direction (the X direction shown in the drawing). As a result, the magnetization of each of both end portions C of the free magnetic layer26is pinned in the same direction as the magnetization direction of the ferromagnetic layers28by ferromagnetic coupling with the ferromagnetic layers28through both end portions27bof the backed layer27.

Alternatively, the constituent elements of both sides portions27bof the backed layer27thermally diffuse to the ferromagnetic layers28and both end portions C of the free magnetic layer26in the second magnetic field annealing, so that both end portions C of the free magnetic layer26and the ferromagnetic layers28can be combined to function as an integrated ferromagnetic layer, and thus both end portions C of the free magnetic layer26can be appropriately pinned in the track width direction.

The amount of the constituent elements of the backed layer27, which diffuse to the surface of the free magnetic layer26, is larger than to the bottom of the free magnetic layer26. Conversely, the amount the constituent elements of the backed layer27, which diffuse to the bottoms of the ferromagnetic layers28, is larger than to the surfaces of the ferromagnetic layers28. The ratio of the diffusing constituent elements of the backed layer27decreases from the surface to the bottom of the free magnetic layer26, while the ratio of the diffusing constituent elements of the backed layer27decreases from the bottoms to the surfaces of the ferromagnetic layers28. These changes in composition can be recognized by a SIMS analyzer (secondary ion mass spectrometer).

On the other hand, the ferromagnetic layers28and the second antiferromagnetic layers29are provided on only both end portions C of the free magnetic layer26without being provided on the central portion D of the free magnetic layer26, and thus magnetization of the central portion D of the free magnetic layer26is not strongly pinned. The magnetization of the central portion D of the free magnetic layer26is put into the single magnetic domain state in the track width direction (the X direction) in a level permitting reversal of magnetization with an external magnetic field.

In the step shown inFIG. 16, each of the ferromagnetic layers28is preferably formed to a thickness of 2 Å to 50 Å.

In the present invention, both end portions C of the free magnetic layer26are not damaged by ion milling in the step shown inFIG. 15, and thus maintain the good magnetic characteristics. Therefore, even when the ferromagnetic layers28are formed to the above small thickness, ferromagnetic coupling with the ferromagnetic layers28can be increased. In the present invention, therefore, unlike a conventional element, the ferromagnetic layers28need not be formed to a large thickness, and thus the exchange coupling magnetic field produced between the ferromagnetic layers28and the second antiferromagnetic layers29can be sufficiently increased. At the same time, the influence of an excessive static magnetic field from the inner end28aof each of the ferromagnetic layers28on the central portion D of the free magnetic layer26can be suppressed, thereby permitting the manufacture of the magnetic sensing element having excellent sensitivity even with a higher recording density.

As described above, the manufacturing method of the present invention can manufacture the magnetic sensing element permitting proper control of the magnetization of the free magnetic layer26, and having the specular layer31having excellent reproduction sensitivity even with a narrower track, as compared with a conventional sensing element.

The magnetic sensing element shown inFIG. 5can be manufactured by the above-described manufacturing method. In the method of manufacturing the magnetic sensing element shown inFIG. 6, both end portions31bof the specular layer31and both end portions27bof the backed layer27, all of which are positioned on both sides of the resist layer50in the track width direction (the X direction), are removed to expose both end portions C of the free magnetic layer26in the step shown in FIG.15.

In the present invention, the total thickness h3of the backed layer27and the specular layer31and the nonmagnetic layer32formed on the free magnetic layer in the step shown inFIG. 14is 20 Å or less. Therefore, in the step shown inFIG. 15, all of both end portions31bof the specular layer31and both end portions27bof the backed layer27can be removed by low-energy ion milling, and milling can easily be controlled to stop at the moment when both end portions27bof the backed layer27are completely removed. In the present invention, therefore, even when both end portions C of the free magnetic layer26are exposed in the step shown inFIG. 15, both end portions C of the free magnetic layer26are less damaged by ion milling, thereby maintaining the magnetic characteristics of both end portions of the free magnetic layer26in a good state. Thus, the magnetization of the free magnetic layer26can be appropriately controlled.

In the method of manufacturing the magnetic sensing element shown inFIG. 7, the specular layer31is formed on the free magnetic layer26in the step shown in FIG.14. Then, in the step shown inFIG. 15, both end portions31bof the specular layer31, which are exposed from both sides of the resist layer50in the track width direction (the X direction), are partially removed to thinly (for example, 0.2 Å to 3 Å) leave both end portions31bof the specular layer31on both end portions C of the free magnetic layer26. Then, the step shown inFIG. 16may be performed.

When the specular layer31is formed to a thickness of as small as 3 Å or less in the step shown inFIG. 14, ferromagnetic coupling can be appropriately produced between both end portions C of the free magnetic layer26and the ferromagnetic layers28, which oppose each other through both end portions C of the specular layer31, without ion milling removal of both end portions31bof the specular layer31. Therefore, the step shown inFIG. 16may be performed without ion milling in the step shown in FIG.15.

In the method of manufacturing the magnetic sensing element shown inFIG. 8, the specular layer31is formed on the free magnetic layer26in the step shown in FIG.14. Then, in the step shown inFIG. 15, both end portions31bof the specular layer31, which are exposed from both sides of the resist layer50in the track width direction (the X direction), are completely removed to expose the surfaces of both end portions C of the free magnetic layer26. Then, the step shown inFIG. 16may be performed.

The methods of manufacturing the magnetic sensing elements shown inFIGS. 1to8are described based on the steps shown inFIGS. 11to16. However, the present invention relates to the magnetic sensing element comprising the specular layer31, and the free magnetic layer26in which the magnetization is controlled in an exchange bias system. Particularly, even when the track is further narrowed with an increased in the recording density, the magnetization of the free magnetic layer26can be appropriately controlled.

Each of the magnetic sensing elements of the present invention shown inFIGS. 1to4(the manufacturing method shown inFIGS. 11to13) is characterized in that the specular layer31and the nonmagnetic layer32are deposited on the free magnetic layer26so that the total thickness of the layers formed on the free magnetic layer26is small (specifically, 20 Å or less).

In order to realize the characteristic, each of the specular layer31and the nonmagnetic layer32must be formed to a small thickness. In the present invention, therefore, an element film comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements is oxidized or nitrided in the vacuum container so that the thin specular layer31, for example, of 3 Å to 10 Å can be formed.

Also, the nonmagnetic layer32is formed by using a material hard to oxidize by air exposure, specifically at least one of Ru, Rh, Pd, Ir, Os, Re, Cr, Cu, Pt, and Au, so that the thin nonmagnetic layer32of 2 Å to 8 Å can appropriately function as the anti-oxidization layer.

As described above, the total thickness of the specular layer31and the nonmagnetic layer32formed on the free magnetic layer26can be decreased. Therefore, in the step of removing the layers formed on both end portions C of the free magnetic layer26by ion milling, the ion milling can be performed with low energy, and thus the surfaces of both end portions C of the free magnetic layer26are less damaged by ion milling, thereby maintaining the magnetic characteristics of both end portions C of the free magnetic layer26in a good state. In the present invention, ferromagnetic coupling produced between both end portions C of the free magnetic layer26and the ferromagnetic layers28formed thereon can be increased, thereby permitting appropriate control of the magnetization of the free magnetic layer26.

In the present invention, the specular layer31is formed by using an oxide or nitride comprising at least one element of Cr, Mo, W, Ti, Si, Ge and Al to impart the function as the anti-oxidation layer to the specular layer31even when the specular layer has a thickness of as small as 3 Å to 15 Å without the nonmagnetic layer31. As a result, the total thickness of the layers formed on the free magnetic layer26can be properly decreased, and thus both end portions C of the free magnetic layer26are not damaged by ion milling, thereby permitting effective control of the magnetization of the free magnetic layer26.

In the present invention, it is possible to manufacture the magnetic sensing element having the specular effect and permitting easy and appropriate control of the magnetization of the free magnetic layer.

In forming a reproducing magnetic head (MR head) by using the above-described magnetic sensing element, gap layers and shield layers are formed on and below the magnetic sensing element. In this case, a lower gap layer and a lower shield layer are formed between the seed layer21and the substrate20. A recording inductive element may be further laminated on the MR head.

The magnetic sensing element of the present invention can also be provided on a built-in magnetic head of a hard disk device, and used for other magnetic sensors.

The above-described magnetic sensing element of the first embodiment of the present invention comprises the specular layer and the nonmagnetic layer formed on the central portion of the free magnetic layer, and the ferromagnetic layers and the second antiferromagnetic layers, which are formed on both end portions of the free magnetic layer.

In the present invention, an element film comprising at least one of Ti, Zr, Hf, V, Nb, Ta, Al, Si, Ge, Cr, Mo, W and the rare earth elements is oxidized or nitrided in a vacuum container so that the thin specular layer, for example, of 3 Å to 10 Å, can be formed.

Also, the nonmagnetic layer is formed by using a material hard to oxidize by air exposure, specifically at least one of Ru, Rh, Pd, Ir, Os, Re, Cr, Cu, Pt, and Au, so that the thin nonmagnetic layer of 2 Å to 8 Å can appropriately function as the anti-oxidization layer.

As described above, the total thickness of the specular layer and the nonmagnetic layer formed on the free magnetic layer can be decreased. Therefore, in the step of removing the layers formed on both end portions of the free magnetic layer by ion milling, the ion milling can be performed with low energy, and thus the surfaces of both end portions of the free magnetic layer are less damaged by ion milling, thereby maintaining the magnetic characteristics of both end portions of the free magnetic layer in a good state. In the present invention, ferromagnetic coupling produced between both end portions of the free magnetic layer and the ferromagnetic layers formed thereon can thus be increased, thereby permitting appropriate control of the magnetization of the free magnetic layer.

In the present invention, the specular layer is formed by using an oxide or nitride comprising at least one element of Cr, Mo, W, Ti, Si, Ge and Al to impart the function as the anti-oxidation layer to the specular layer even when the specular layer has a thickness of as small as 3 Å to 15 Å without the nonmagnetic layer. As a result, the total thickness of the layers formed on the free magnetic layer can be properly decreased, and thus both end portions of the free magnetic layer are not damaged by ion milling, thereby permitting effective control of the magnetization of the free magnetic layer.

As described above, in the present invention, it is possible to manufacture a magnetic sensing element capable of effectively controlling the magnetization of a free magnetic layer and appropriately complying with a narrower tack, as compared with a conventional magnetic sensing element.