Abstract:
A PMR head comprises a substrate, a magnetic pole formed over the substrate, the pole having a pole tip having a cross-sectional tapered shape wherein the pole tip is surrounded by a write gap layer, an integrated shield comprising side shields on the substrate laterally surrounding the pole tip and a trailing shield overlying the pole tip and integral with the side shields.

Description:
This is a divisional application of U.S. Ser. No. 12/072,272 filed on Feb. 25, 2008 now U.S. Pat. No. 8,056,213. 
     RELATED PATENT APPLICATION 
     U.S. patent application Ser. No. 11/906,717 filed on Oct. 3, 2007 and assigned to the same assignee of the present invention, and herein incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     This invention is related to magnetic recording heads and, more particularly, to shielding of perpendicular magnetic recording heads. 
     (2) Description of the Related Art 
     In order to push for high track density perpendicular magnetic recording (PMR), it is necessary to have side shield PMR design to reduce fringe and to improve side erasure. There are several proposals to use subtractive methods such as reactive ion etching (RIE) or ion beam etching (IBE) to etch into the magnetic shield followed by atomic layer deposition (ALD), plating, and chemical mechanical polishing (CMP) methods to form side shield PMR. However, all these proposals do not have a self-aligned structure between the side shield and the trailing shield. 
     U.S. Pat. No. 7,002,775 to Hsu et al discloses side and trailing shields, but provides no details about how they are made. U.S. Pat. No. 7,253,991 to Fontana, Jr. et al teaches side and trailing shields formed by CMP, but they are not self-aligned. U.S. Pat. No. 7,068,453 to Terris al el and U.S. Patent Application 2007/0253107 to Mochizuli et al teach that side and trailing shields may be a single piece or they may be separate pieces. U.S. Pat. No. 7,070,698 to Le shows side shields and trailing shields formed separately. Co-pending U.S. Patent Application 2007/0177301 to Han et al, filed on Feb. 2, 2006, discloses a method of forming side shields where the pole tip is aligned to the side shields and then forming an upper shield over the side shields. 
     U.S. Patent Applications 2007/0186408 to Nix et al and 2006/0044682 to Le et al teach self-aligned wrap-around side and trailing shields. However, the main pole in these inventions is formed by deposition and etching processes. 
     In co-pending patent application Ser. No. 11/906,717 (HT07-016) filed on Oct. 3, 2007, a method is proposed to make a self-aligned full side shield PMR.  FIG. 1  shows the air-bearing surface (ABS) view of this self-aligned full side shield PMR head. Main pole  16  is surrounded by write gap  24 . Self-aligned full side shield  26  surrounds the pole. Trailing shield  28  overlies the side shield. However, using two separate processes to fabricate the side shield and the trailing shield creates interface flux choking at the interface between the side and trailing shields. Adjacent track erasure (ATE) problems were observed due to this flux choking. 
     SUMMARY OF THE INVENTION 
     It is the primary objective of the present invention to fabricate both side shields and trailing shield of a PMR head in one fabrication process. 
     In accordance with the objective of the invention, a PMR head comprises a substrate, a magnetic pole formed over the substrate, the pole having a pole tip having a cross-sectional tapered shape wherein the pole tip is surrounded by a write gap layer, an integrated shield comprising side shields on the substrate laterally surrounding the pole tip and a trailing shield overlying the pole tip and integral with the side shields. 
     Also in accordance with the objective of the invention, there is disclosed a method of fabricating a PMR head. An alumina layer is deposited on a substrate and a trench is formed through the alumina layer to the substrate. A first seed layer is deposited over the alumina layer and within the trench. A magnetic main pole is formed on the seed layer wherein the magnetic main pole comprises a main pole area and a pole tip area. The first seed layer not underlying the magnetic main pole is removed. The alumina layer is removed to create a cavity around the pole tip area of the magnetic main pole. A second seed layer is deposited over the substrate within the cavity. An integrated side shield is formed on the second seed layer and overlying the pole tip area. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional representation of a self-aligned full side shield of co-pending patent application Ser. No. 11/906,717. 
         FIG. 2  is a cross-sectional representation of the self-aligned integrated side shields of the present invention. 
         FIGS. 3-8  are cross-sectional representations of the process of the present invention. 
         FIG. 9A  is a side view and  FIG. 9B  is a top view of a step in the process of the present invention. 
         FIG. 10A  is a cross-sectional view and  FIG. 10B  is a top view of a step in the process of the present invention. 
         FIG. 11A  is a cross-sectional view and  FIG. 11B  is a side view of a step in the process of the present invention. 
         FIGS. 12 and 13  are top views of steps in the process of the present invention. 
         FIG. 14A  is a cross-sectional view and  FIG. 14B  is a top view of a step in the process of the present invention. 
         FIG. 15  is a top view of a step in the process of the present invention. 
         FIG. 16A  is a cross-sectional view and  FIG. 16B  is a top view of a step in the process of the present invention. 
         FIG. 17A  is a cross-sectional view and  FIG. 17B  is a side view of a step in the process of the present invention. 
         FIG. 18  is a side view of the completed PMR head of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention provides a method for fabricating self-aligned integrated side and trailing shields for a PMR head. This method fabricates the integrated shields in one process so as to prevent interface flux choking.  FIG. 2  shows the completed self-aligned integrated side shield of the invention. Main pole  16  is shown surrounded by write gap  23 . Integrated side and trailing shield  30  is fully aligned to the main pole. 
     The fabrication process of the present invention will be described with reference to the drawing figures. Referring now to  FIG. 3 , an ABS view shows the first steps in a process sequence of the present invention. A separation layer  12  made of a dielectric material such as alumina is provided on a substrate  10 . Substrate  10  may be an etch stopper material, for example. The alumina layer  12  is formed to a thickness of between approximately 2000 and 4000 Angstroms by a process of physical vapor deposition (PVD), for example. Referring now to  FIG. 4 , a trench  13  is etched through the alumina layer  12  to the substrate  10 . Now, a seed layer  14  is deposited conformally over the alumina layer  12  and into the trench  13  using atomic layer deposition (ALD) to form a uniform side gap, as shown in  FIG. 5 . The seed layer is preferably Ru, formed to a thickness of between about 300 and 500 Angstroms. The layer  14  also acts as a CMP stopper. 
     Referring now to  FIG. 6 , the magnetic main pole  16  is electroplated onto the seed layer  14  in the trench area. The magnetic pole layer is preferably a layer of low coercivity magnetic material such as NiFe, CoNiFe, FeCoNi, or FeNi, for example, and it is plated to a thickness sufficient to fill the trench in a void-free manner, typically about 0.5 to 1 micron in thickness. 
     Then, a CMP process is performed to planarize the main pole material  16  to the main pole and Ru interface, as shown in  FIG. 7 . Next, the Ru layer not underlying the main pole material is removed, for example, using IBE.  FIG. 8  shows the ABS view after etching away of the Ru layer.  FIG. 9A  shows a side view of the center line and  FIG. 9B  shows a top view of the main pole piece at this step in the fabrication process.  FIG. 8  shows the view B-B′ of the top view in  FIG. 9B .  FIG. 9A  shows the view A-A′ of the top view in  FIG. 9B . 
       FIG. 10A  shows the ABS view and  FIG. 10B  shows the top view of the next step in the process, where the view B-B′ of  FIG. 10B  is shown in  FIG. 10A . A photoresist mask, not shown, is formed over the alumina layer  12  and the main pole region. The alumina  12  is removed using, for example, IBE followed by an alkaline solution treatment, where it is not covered by the mask, not shown, to create a cavity  19  around the selected main pole tip area, as shown in  FIGS. 10A and 10B . 
     Next, as shown in the ABS view in  FIG. 11A  and in side view in  FIG. 11B , a second Ru layer  20  is deposited, preferably by ALD, over the substrate  10  in the cavity areas around the main pole and over the main pole  16 , as shown. The sidewall areas of the main pole, as shown in  FIG. 11A , comprise the first Ru layer  14  and the second Ru layer  20  thereover. The first and second Ru layers  14  and  20  together act as a partial side shield gap and write gap. The total write gap layer has a preferred thickness of between about 300 and 500 Angstroms. 
     Referring now to  FIG. 12 , a via opening for the top yoke is made through the Ru layer  20  to expose the main pole  16 . This is preferably performed by IBE, and followed by a magnetic seed layer deposition  17  such as CoNiFe or NiFe, as shown in  FIG. 13 . Now, a writer shield photo pattern is made using a negative resist process. Mask  22  is shown in top view in  FIG. 13 . 
       FIG. 14A  shows the ABS view and  FIG. 14B  shows the top view of the next step in the fabrication process. Shield material  30  is plated on the Ru layer  20 . The Ru layer  20  acts as a seed layer for the purpose of the plating process. The shield material is a layer of magnetic material such as FeNi, CoNiFe, FeCoNi, or NiFe and it is plated to a thickness of approximately 2 microns. This plating process also forms the top yoke  36 , shown in  FIG. 14B . 
     The plating seed layer  20  not covered by the shield material  30  is removed by IBE, as shown in top view in  FIG. 15 . 
     Referring now to  FIGS. 16A and 16B , the structure is covered with alumina  32  deposited by a high rate ALD or PVD process. 
     Now, a CMP process is performed to form the trailing portion of the integrated shield to the target thickness of about 0.6 micron, as shown in the ABS view in  FIG. 17A  and in side view in  FIG. 17B . 
     Finally, the PMR writer is completed, as known in the art. For example, side view  FIG. 18  shows spirally wound electrically conducting coils formed about the magnetic pole  16 . Insulator  54 , read shields  56 , and write shield  58  are also shown. 
     The present invention provides an integrated side shield PMR head structure, as illustrated in  FIG. 2 . There is no interface between the side shield and the trailing shield since it is formed in one process step. The integrated side shield  30  surrounds and overlies the main pole tip  16 . Write gap layer  23  comprises first and second Ru layers  14  and  20 , respectively. The magnetic main pole has a preferred width of between about 50 and 500 nm. 
     The integrated side shield PMR head structure of the present invention comprises a tapered main pole or tapered write gap with side shield design to reduce side fringe for further enhancement of tracks per inch (TPI), a better track profile, and elimination of adjacent track erasure (ATE) caused by flux choking at the side shield and trailing shield interface. 
     Although the preferred embodiment of the present invention has been illustrated, and that form has been described in detail, it will be readily understood by those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.