Abstract:
A method of manufacture for forming a novel magnetic read/write transducer head of the type utilizing thin film materials. The method of manufacture comprises steps which deposit a thin film magnetic recording head on a selected substrate having dimensions which enable batch manufacture of a thin film magnetic transducer in combination with its supporting slider assembly. The substrate of selected material in thick wafer form is subjected to a series of thin film deposition, etching and plating operations to form a plurality of thin film magnetic heads thereon. Thereafter, the substrate wafer is diced around each thin magnetic transducer head with subsequent finishing and polishing to requisite shape thereby to yield the complete slider and transducer head assembly. A particular form of thin film magnetic transducer head is further novel in that the head utilizes shield and pole pieces that are formed as multi-layer thin film pairs of magnetic material as deposited in order and formation to contain the magnetoresistive stripe and operative elements. The multi-layer pole depositions may be further altered as to number of thin film layers and thickness thereof in order to shape the magnetic fields associated therewith, especially as regards the trailing edge or write pole formation.

Description:
RELATED APPLICATIONS 
     This is a continuation-in-part of U.S. Patent Application Ser. No. 830,104, filed on Sept. 2, 1977. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates generally to magnetic transducer heads and, more particularly, but not by way of limitation, it relates to an improved method of manufacture and article of the thin film magnetic type of read/write transducer head as used in high speed applications for data sensing relative to record media such as tapes, drums, disks and the like. 
     2. Description of the Prior Art 
     The prior art includes numerous types of inductive and magnetoresistive recorder heads of the type which utilize thin film technology in formation. Such prior transducer heads utilize various thin film configurations, often times dictated by the particular intended use, and generally speaking the prior transducer head assemblies have utilized unitary thin film elements such as shields, poles and other effective surfaces within the head assembly. A U.S. Pat. No. 3,867,368 in the name of Lazzari does disclose a single multi-layer thin film element in an inductive type transducer head. 
     The prior art also discloses numerous modes for deposition fabrication of thin film magnetic transducer heads, such processes including the well-known steps of deposition, etching, plating, etc. However, in prior fabrication of the thin film magnetic heads, it was necessary to first fabricate the transducer head and thereafter to bond the transducer head onto a selected slider of the type used in high speed recorder applications. The various processes attendant formation of a thin film magnetoresistive transducer head are thoroughly discussed in U.S. Pat. No. 3,908,194 in the name of Romankiw and this patent even deals with batch fabrication of such magnetic heads. In this teaching, there is utilized a magnetically shielding substrate composed of a ferrite material, and after fabrication of the transducer head it is still necessary to bond the finally produced head to a slider or other support mechanism that may be used in conjunction therewith. 
     SUMMARY OF THE INVENTION 
     The present invention contemplates a method of manufacture for forming a thin film magnetic read/write transducer head in situ on a supporting slider element. The method consists of selecting a substrate of a thickness consonant with the length of transducer slider, and thereafter forming in designated areas on top of the substrate wafer a plurality of thin film magnetic transducer heads utilizing the well-known thin film deposition, etching and plating techniques. Thereafter, the substrate wafer is diced and each individual section is finished and polished to yield a complete slider with thin film composite head (i.e., magnetoresistive read and inductive write) or inductive head, and electrical contacts borne thereon in operative disposition. One type of thin film magnetoresistive transducer head that is contemplated is of the type that utilizes thin film layers which form a read shield, sensor, bias layer, shield pole and trailing edge pole, and each of the read shield, shield pole and trailing edge pole are made up of a plurality of alternating pairs of thin film layers of selected magnetic material. The bias layer is further deposited as a thin film of permanent magnet material immediately adjacent the read sensor thin film layer of magnetoresistive material. 
     Therefore, it is an object of the present invention to provide a magnetic recording head that provides high reading efficiencies and small dimensions, thus achieving high recording densities. 
     It is also an object to provide a thin film magnetoresistive transducer head that includes a shaped write field in order to avoid high reverse field in the trailing edge of the write pole. 
     It is still further an object to provide such a thin film transducer head of the magnetoresistive type that includes an oriented magnetoresistive stripe enabling uniform and repeatable device performance. 
     It is yet another object of the present invention to provide a thin film magnetoresistive transducer having multi-layer element poles and shields with the trailing edge pole modified in order to yield a significantly improved write characteristic. 
     Finally, it is an object of the present invention to provide a method of manufacturing a slider and magnetic transducer head, either magnetoresistive or inductive, in combination by depositing the thin film structure on a thick substrate whose thickness is approximately equal to that of the desired length of the recording head slider so that a completely finished integrated recording head can be produced with fewer process steps. 
     Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawings which illustrate the invention. 
    
    
     Brief Description of the Drawings 
     FIG. 1 is a perspective view of a substrate wafer with coordinate areas generally designated on a portion of the surface, and including the deposited thin film magnetic transducer heads thereon; 
     FIG. 2 is a perspective view of a finished slider and thin film transducer head as constructed in accordance with the method of the invention; 
     FIG. 3 is an alternative construction of slider and plural transducer head assembly as may be constructed in accordance with the present method of manufacture; 
     FIG. 4 is a perspective view, greatly enlarged, of a finished thin film recorder head in disposition on its associated slider; 
     FIG. 5 is a partial sectional view, greatly enlarged, of a multi-layer thin film pole or shield of the type utilized in the transducer structure of FIG. 4; 
     FIG. 6 is a partial sectional view, greatly enlarged, of a multi-layer thin film trailing edge pole as utilized in the structure of FIG. 4; and 
     FIG. 7 is a perspective view in exploded form illustrating further the operative elements of the recorder head of FIG. 4. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1, a wafer of suitable substrate 10 is shown with a plurality of coordinate areas delineated by dicing lines 12 and transverse dicing lines 14. In actual practice, the wafer of substrate 10 may be any of several substances, e.g., a silicon or ferrite wafer of designated thickness t which is commercially available in standard diameters ranging from 21/4&#34; to about 4&#34;. Thus, the coordinate areas laid out over the entire surface face 16 of substrate wafer 10 would be very great in number since a magnetic transducer package 18 deposited within a coordinate area would have dimensions of a few mils square. Thus, a very great number of magnetic transducer head packages 18, either inductive or composite, may be simultaneously deposited on wafer surface 16 by means of conventional deposition, masking, etching and plating techniques, as will be further described below. 
     After formation of the large plurality of magnetic transducer head packages 18 within each coordinate area, the substrate wafer 10 may be cut along each of dicing lines 12 and dicing lines 14 across the whole expanse of the wafer thereby to produce a large plurality of individual substrate/package combinations which are then finished and polished into a transducer-slider combination 20 as shown in FIG. 2. Thus, the substrate wafer 10 portion having thickness t becomes the slider 22 portion of the transducer head bearing on one end thereof the formation of the magnetic transducing head package 18 which includes a magnetic head 24 with plated or deposited conductors, i.e., write conductors 26 and read conductors 28, as will be further described. Finishing of the diced wafer section and completion of the slider assembly shaping includes the provision of a transverse slot 30 cut in the top portion of slider 22, beveling of opposed lower corners to form bevel surfaces 32 and 34, and final polishing of the flying surfaces 36 across the underside. Thus, there is formed a complete slider-transducer head assembly 20 in relatively fewer process steps that is ready for operational usage. 
     FIG. 3 illustrates a finished triple head slider 40 that is manufactured in a similar type of process, it only being necessary to change the coordinate layout of substrate wafer surface 16 for coaction with the particular scheme of deposition patterns, etching masks, and other incidental patterning which may be attendant. The triple head slider 40 is formed with length t equal to the depth of substrate wafer 10 and is then finally finished and polished to include a transverse slot 42 and a plurality of bevel edges 44 that define underside flying surfaces 46, 48 and 50 coplanar with the sensing stripes of thin film transducer head packages 52, 54 and 56, respectively. The plating or deposition process also provides the requisite read and write conductor leads for each of heads 52, 54 and 56 as exposed for contact on the wafer surface portion or end 58 of slider 40. Such multi-track slider recording head assemblies may be formed for any multiple of thin film recording heads, and these may be batch formed by utilizing the requisite deposition and masking procedures. 
     FIG. 4 illustrates in greatly enlarged form magnetoresistive read/write transducer head 60 as it is particularly constructed in accordance with the present invention. The depiction of FIG. 4 shows the substrate 62 (the slider portion) in finished form as it would be shaped and polished for final operational usage. At the present time, the substrate 62 is selected to be of silicon since it has desirable high heat conductivity and surface smoothness that aids in receiving thin film depositions thereon. The silicon material also lends itself to milling and machining for formation of the final slider assembly. 
     During formation of magnetoresistive head 60, the substrate 62 is first overlaid with a first deposition surface 64 of insulator material that is non-magnetic in character and of hard dielectric quality. Such insulated material may be such as AL 2  O 3 , Si 3  N 4  or other oxides of silicon, all materials having requisite properties that are easily deposited and conducive to various etching techniques. Or, in the case of silicon substrate, the initial surface can be heat treated in an oxidizing atmosphere to form a layer of silicon dioxide, a well known art in the semi-conductor industry. Next is deposited a read shield 66, a multi-layer magnetic structure that is made up of an even number of pairs of Nickel-Iron thin film with a thin SiO 2  or Titanium film layer in alternation. Thus, the even numbered pairs of thin films form magnetostatically coupled pairs, and serve to lower the total magnetic energy required as well as to remain in stable domain position along a preferred direction. 
     FIG. 5 illustrates a portion of thin film shield 66 in enlarged form. Thus, a first deposition may be such as silicon dioxide (SiO 2 ) to a thickness of from 20 to 1000 Angstroms, and the pairs would then consist of successive overlaps of thin film Nickel-Iron (NiFe), each to a thickness of from 500 to 2,000 Angstroms. The thickness of the SiO 2  thin film 68 and NiFe thin films 70 may be varied within considerable limits thereby to alter the magnetic properties and response characteristics in desired manner. Accordingly, shield 66 is then finally formed by the stacking of a plurality of such pairs of thin films 70, as successively applied by deposition and as separated by intersticed formations 68. In device fabrication, the multi-layer thin films 68-70 may be deposited successively by any of several well-known techniques, including vacuum evaporation of sputtering techniques, and the operation can be performed in a single vacuum pump down. The pattern limits of thin film may then be etched either by chemical etching, sputter etching, or by the ion-milling method. 
     A relatively thin film of insulator 72 (see FIG. 4) is then deposited over the shield 66, and the insulator once again may be Al 2  O 3  or the well-known glass compositions including SiO 2  and related silicates and silicon nitride. A magnetoresistive (MR) sensor 74 is then deposited to overlay the shield 66 in insulatively spaced disposition. Sensor 74 consists of a deposition of magnetoresistive material, such as NiFe alloy, and suitable conductive contact layer is formed in extension, as at 76 and 78, to receive electrically conductive contact with plated conductors 80 and 82. Referring also to FIG. 7, conductor films 80 and 82 may be formed by conventional conductor deposition of such as gold, aluminum or the like as applied using flashing and plating processes through the requisite masking. The thin film MR sensor 74 may be deposited or sputtered to a thickness ranging from 200 through 500 Angstroms, depending upon the desired characteristics to be imparted to the magnetic read head. 
     The next thin film of insulator material, e.g., the similar glass or glass-like materials as previously specified, is deposited across conductors 80 and 82 and the MR sensor 74. This surface then receives deposition of a bias thin film 86 which consists of a thin film deposit of suitable permanent magnet material such as Alnico or other high remanence alloy. The permanent magnet bias thin film 86 provides control of thin film domain orientation within the read elements. Another deposition of insulator 88 then overlays bias thin film 86 to receive deposition in properly spaced manner of a shield pole 90 which may be identical to the pole 66 as shown in enlarged form in FIG. 5. Thus, shield pole 90 consists of successive layers of magnetostatically coupled pairs of SiO 2  or Ti and NiFe thin films to a requisite stacking height, for example, on the order of 20,000 Angstroms. The shield pole 90 is also then overlaid with an insulator film 92 of the same type previously used, to receive deposition of a write conductor 94 as disposed for inductive coupling to its associate write poles. The write conductor 94 may be formed in requisite pattern by sputtering with subsequent plating of conductive material to desired thickness. 
     A final insulative thin film 96 is then applied to recieve thereon a trailing edge pole 98 of the multi-layer thin film type. Thus, trailing edge pole 98 also consists of a stack of magnetostatically coupled pairs of NiFe thin films 102-102n; however, the thickness and arrangement is altered in order to shape the write field of the unit. Thus, as shown in FIG. 6, the pairing of the NiFe thin film 102 are utilized to form the stacked pairs of magnetostatically coupled thin films; however, the write pole element is desirably shaped by progressively reducing the thickness of successive thin films 102 proceeding toward the trailing edge of the record head 60. This is illustrated in FIG. 6 as it can be seen that the upper two thin films to film 102n are each of proportional diminution relative to the base thin film 102. 
     Referring again to FIG. 4, each of shield 66, shield pole 90 and trailing edge pole 98 are of generally square planar expanse within the record head 60. Thus, the transverse dimension illustrated by arrow 104 may be of the order of 0.5 to 1.4 mil as defined by the recording track density requirements, and the dimension perpendicular thereto, or the depth of the respective shields and poles, may be patterned to be approximately the same or larger extending the film stack in direction 130. The final stacked thin film structure is then encapsulated by suitable passivation material such as glass or other hermetically sealing material as applied in a coating 106 and, if desired, a thin coating of such passivation material 106 may be extended over the entire magnetic head face to be finally finished in conjunction with the flying surface of substrate 62. 
     The read and write conductors are shown generally as being sputtered and plated on the sides of recording head 60. In FIG. 4, the write conductors 110 and 112 and read conductors 114 and 116 may be formed by any of several acceptable integrated circuit techniques to provide the proper conductor continuity, shown generally for write conductor 94 by dash lines 118 and 120, and for read conductor 80 and 82 by means of dash lines 122 and 124. Such connections may be made for example by provision of deposition and plating with proper masking and etching during the actual thin film deposition process with subsequent bonding or plating of external lead connectors, as is well known in the art. Such techniques are fully described in the aforementioned U.S. Pat. No. 3,908,194 to name but a single source. 
     FIG. 6 better illustrates the manner of formation of the read and write conductors as they are deposited, etched and plated during the thin film formation process. Thus, after deposition of the MR film 74, with provision of extensions 76 and 78, the metal conductors 80 and 82 are formed, adjacent thereto and in electrical contact, to extend outward and rearward in hairpin configuration (116 and 114) where subsequent contact procedures will enable external terminal connections. In like manner, after formation of insulative film 92 (FIG. 4) in overlay on shield pole 90, the inductive write conductor 94 is similarly deposited and plated to extend lateral rearward conductor portions 112 and 110 for formation of external write terminals. The numerous insulative films are omitted from FIG. 6 for clarity, but they would of course be present in final formation and the passivation coating 106 is then applied over the entire thin film formation with exposure of only the terminal contacts for read conductor plates 116 and 114, and write conductor plates 112 and 110. 
     When in operation, the slider transducer head assembly is positioned for sensing with the recording medium moving in the direction of the arrow 132 in FIG. 4, i.e., perpendicular to the shield 66, shield pole 90 and trailing edge pole 98. In the read mode, the sensor 74 provides magnetoresistive pickup as energy change information is conveyed by direct connection to the read conductors 80 and 82. Domain orientation of the magnetoresistive sensor 74 is assured by the permanent magnet bias thin film 86 overlaid thereon in insulative disposition. The polar elements in read mode are the shield 66 and shield pole 90 which functions as a shield during read operation, thus defining the magnetoresistive stripe at the read sensing interface. In write mode, shield pole 90 then functions as a leading edge pole in conjunction with the trailing edge pole 98, and inductive coupling to the write conductor 94 provides output of write indication via write conductors 110 and 112. 
     The foregoing discloses both a method of manufacture and an improved light-loading magnetic recording head of the thin film magnetoresistive type. The present invention utilizes an entirely different form of transducer element formation by multi-layer thin film deposition, and such manipulation of the degree and type of homogeneity of transducer element greatly enhances the versatility and applications for thin film magnetic transducers of either the inductive or magnetoresistive type. While the foregoing description makes reference to certain dimensions and materials, it should be understood that there are numerous materials suitable for construction of thin film magnetic heads as described, and the particular thin film dimensions may also be subject to wide variation depending upon operational attributes of a particular magnetic transducer. 
     Changes may be made in the combination and arrangement of elements as heretofore set forth in the specification and shown in the drawings; it being understood that changes may be made in the embodiments disclosed without departing from the spirit and scope of the invention as defined in the following claims.