Abstract:
Methods and structures for the fabrication of a thin film, longitudinal and perpendicular recording heads are disclosed. The heads comprise a plurality of embedded static dissipative layers that extend a few nanometers from the air bearing surface. These extended layers are first to contact the magnetic media surface and drain any electric charge buildup before a damaging discharge occurs with read or write head components. The embedded static dissipative layers are particularly useful for use in heads utilizing thermal fly height control systems, which tend to increase the probability of damaging electrical discharge through critical head components.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to structures and methods for fabricating thin film magnetic read and write heads. More specifically, the invention relates to structures and methods for fabricating a thin film recording head having reduced sensitivity to electrical breakdown resulting from electrostatic discharge from media surfaces. 
     2. Description of the Related Art 
     The extremely small dimensions of structures comprising the read and write components of today&#39;s hard disk drive thin film magnetic heads makes these heads susceptible to damage by electrostatic discharge sources. One important source is the disk media itself, where static charge potentials on the order of a few volts can damage a thin film head and the media surface if a voltage breakdown or electrical discharge occurs between the head and disk media. As fly heights decrease in response to demands for increased areal densities, a catastrophic discharge becomes more likely. The onrush of current produced by a discharge can damage both the sensitive thin film read devices as well as write devices in both longitudinal and perpendicular thin film heads. This problem is further exacerbated in heads having thermal fly height control (TFC), since the physical distortion of the thin film head produced during heating tends to extend the critical read and write structures toward the media disk, making them closer than the slider body and the nearest “lightening rods”. 
     Disclosure in the art have suggested a number of potential solutions to solve this problem. In some cases, semi-conductive layers embedded in the thin film heads have been proposed. These layers, however, are typically flush with the air bearing surface, along with other layers such as magnetic pole layers and shield layers. They are therefore ineffective in draining charge from a media surface, as the discharge will more likely be attracted to the metallic pole layers or shield layers. If this occurs, device damage will occur with or without the semi-conductive layers. Other references have suggested the use of a coating applied over the ABS. The problem with this technique is that the coating impacts the very critical head to surface dimensions which are on the order of 5 to 10 nm currently, and may drop to a few nanometers in the future. Thus, the thin coating itself will breakdown, resulting in a damaging current discharge. It is also difficult to reliably produce coatings on the order of a few nanometers that can carry the required current without being damaged themselves. What is needed is a better method to protect thin film magnetic heads from voltage breakdown. 
       FIG. 1  (Prior Art) is a partial cross sectional view  100  of a typical thin film longitudinal head, wherein the write head comprises write gap  112  bounded by upper  110  and lower  108  pole tips. Upper pole tip  110  is in contact with upper return pole layer  114 . Lower pole tip  108  is in contact with lower return pole layer  106 . Lower return pole layer is separated from shield layer  102  by insulating layer  104 . The coil is shown as structure  116 , embedded in insulating layer  118 , which may also be referred to as an overcoat layer. The read head comprises a MR (magneto-resistive) sensor  103  located between upper  102  and lower  101  shield layers. Shield layer  101  is supported by undercoat layer  120  and an AlTiC base layer  122 . 
       FIG. 2  (Prior Art) is a partial, cross sectional view  200  of a typical thin film perpendicular head. The head comprises shield layers  202 ,  204 , MR sensor  203 , shaping layer  210 , coil structure  208 , main pole  212 , lower return pole layer  206 , wrap around shield  214 , and upper return pole layer  216 . Alternatively, structure  214  may also be a trailing shield. Shield layer  202  is supported by undercoat layer  218  and an AlTiC base layer  220 . Details of wrap around shields and trailing shields, as applied to perpendicular recording heads, can be found in, for example, US Patent Application Publications 2007/0146930, 2007/0115584, 2006/0174474, 2006/0044682, and 2007/0137027. 
       FIG. 3  (Prior Art) is a partial cross sectional view  300  of a thin film longitudinal head undergoing thermal expansion during thermal fly height control. Thermal fly height control engages the use of heaters embedded within the thin film head structure (not shown) to cause distortion of the air bearing surface (ABS) when the head is heated. Thermal expansion of materials within the head cause the dynamic position of the ABS to move toward the disk surface. This alters the effective fly height of the head over the media disk surface. In  FIG. 3 , the dashed line marked ABS c  indicates the position of the air bearing surface in an unheated condition (as in  FIG. 1 ). The dashed line marked ABS h  indicates the distorted position of the air bearing surface subsequent to heating. Unfortunately, the distortion produced by the thermal fly height control heaters make critical components such as shield layers  101 ,  102 ; sensor  103 ; pole tips  110 ,  108 ; and lower pole layer  106  more susceptible to damage by electrostatic discharge from the media disk surface. 
       FIG. 4  (Prior Art) is a partial, cross sectional view  400  of a thin film perpendicular head undergoing thermal expansion during thermal fly height control. As was discussed with the longitudinal head of  FIG. 3 , distortion produced by the thermal fly height control heaters make critical components more susceptible to damage by electrostatic discharge from the media disk surface in this design as well. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a thin film magnetic head including a read head structure; a write head structure, the read head structure and the write head structure sharing a common air bearing surface; a first electrostatic dissipative layer, disposed between the read head structure and the write head structure, a portion of the first electrostatic layer extending beyond the air bearing surface by a distance D, distance D being between 1 and 5 nm. 
     It is another object of the present invention to provide a thin film magnetic head including a read head structure; a write head structure, the read head structure and the write head structure sharing a common air bearing surface; a first electrostatic dissipative layer, disposed between the read head structure and the write head structure, a portion of the first electrostatic layer extending beyond the air bearing surface by a distance D, distance D being between 1 and 5 nm. The structure further includes a second electrostatic dissipative layer, located such that the read head structure is disposed between the first electrostatic dissipative layer and the second electrostatic dissipative layer, a portion of the second electrostatic layer extending beyond the air bearing surface by distance D; and, a third electrostatic dissipative layer, located such that the write head structure is disposed between the first electrostatic dissipative layer and the third electrostatic dissipative layer, a portion of the third electrostatic layer extending beyond the air bearing surface by distance D. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be better understood when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings, wherein: 
         FIG. 1  (Prior Art) is a partial cross sectional view  100  of a typical thin film longitudinal head; 
         FIG. 2  (Prior Art) is a partial, cross sectional view  200  of a typical thin film perpendicular head; 
         FIG. 3  (Prior Art) is a partial cross sectional view of a thin film longitudinal head undergoing thermal expansion during thermal fly height control; 
         FIG. 4  (Prior Art) is a partial, cross sectional view of a thin film perpendicular head undergoing thermal expansion during thermal fly height control; 
         FIGS. 5 ,  6 , and  7  are partial, cross section views of a thin film longitudinal heads having embedded electrostatic dissipation layers, in accordance with embodiments of the present invention; 
         FIG. 8  is a partial cross section view of a thin film longitudinal head having embedded electrostatic dissipation layers, subsequent to heating by a thermal fly height control system, in accordance with an embodiment of the present invention; 
         FIGS. 9 ,  10 , and  11  are partial, cross section views of a thin film perpendicular heads having embedded electrostatic dissipation layers, in accordance with embodiments of the present invention; and, 
         FIG. 12  is a partial cross section view of a thin film perpendicular head having embedded electrostatic dissipation layers, subsequent to heating by a thermal fly height control system, in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIGS. 1-4  (Prior Art) have been discussed above in the Background section. 
       FIG. 5  is a partial, cross section view  500  of a thin film longitudinal head having embedded electrostatic dissipation layers, in accordance with an embodiment of the present invention. Layers  502 ,  504 ,  506 ,  508 , and  510  are electrostatic dissipative layers inserted within the longitudinal head structure to drain electrical charge from the storage media surface (not shown) in a controlled manner, thus reducing the electrical potential difference that leads to breakdown. Their purpose is to prevent rapid discharge of the electrical charge thorough sensitive components such as the MR read sensor  103  and shield layers  101 ,  102 ; or the write head components comprising upper pole tip  110 , lower pole tip  108 , and lower return pole layer  106 . Typically, this discharge occurs if the head makes contact with (or is in extremely close to) the media disk surface. Electrostatic dissipative layers  502 ,  504 ,  506 , and  510  have a resistivity between that of a conductor and that of an insulator, and may be generally described as “semi-conductive” or “static dissipative”. The electrostatic dissipative layers have a sheet resistance of between 10 5  and 10 11  ohms/square, providing a resistance to the slider body (the ground reference) of between 10 6  and 10 12  ohms. An important aspect of present invention is that static dissipative layers  502 ,  504 ,  508 , and  510  extend out beyond the nominal location of the ABS by a dimension D L . Dimension D L  is less than the nominal fly height of the head, preferably less than about 5 nanometers, more preferably less than 2 nm, most preferably less than 1 nm. This distance is sufficient to ensure that if contact is made between the head and the media disk surface, the electrostatic dissipative layers make contact with the media surface to drain any built up electrical charge. A plurality of layers is provided for a number of reasons. First, the precise location where the head structure may touch the media surface is indeterminate, and may be dependent on a number of variables such as expansion effects due to heating by the thermal fly height control system, and pitch attitude angle. Secondly, it is desirable to protect both the read structures as well as the write structures from damage. Layers  508  and  510  protect the write head components, whereas layers  504  and  506  protect the MR read sensor  103  and adjoining shield layers  101  and  102 . Thirdly, multiple layers need only extend a small distance to minimize D L , whereas a single layer situated between the write structures and the read structures, for example, would need to extend out further from the ABS to assure no contact would be made with any other part of the head. It is desirable to keep D L  at a minimum to avoid any impact on the read or write functions of the head. 
     Electrostatic dissipative layers  502 ,  504 ,  506 ,  508 , and  510  made be made from any material compatible with thin film head manufacturing techniques having the resistivity values mentioned above. Examples of such materials include, but are not limited to, diamond like carbon (DLC), poly-silicon, compounds of Al—N, compounds of Al—Si—N, compounds of Al—O—N, and compounds of Al—O—N—Si. Of the foregoing, DLC is preferred. The extension of the electrostatic dissipative layers from the ABS can be produced with a number of methods. Very hard materials, such as DLC, will tend to extend from the ABS during the lapping steps used to finalize the position of the ABS. This is due to the fact that lapping rates of hard materials such as DLC are much lower than lapping rates of the other layers. Other methods may also be employed such as ion milling, sputtering, wet etching, and dry etching. Each can be chosen to preferentially removed material between the electrostatic dissipative layers subsequent to lapping. 
       FIG. 6  is a partial, cross section view  600  of a thin film longitudinal head having embedded electrostatic dissipation layers, in accordance with an embodiment of the present invention. In this embodiment, layers  502  and  504  of  FIG. 5  have been combined into layer  602  to provide better protection from contact of the slider portion of the head assembly. 
       FIG. 7  is a partial, cross section view  700  of a thin film longitudinal head having embedded electrostatic dissipation layers, in accordance with an embodiment of the present invention. In this embodiment, layers  506  and  508  of  FIGS. 5 ,  6  have been combined in layer  702  to simplify the structure, reducing the number of layers. The semi-conductive properties of layer  702  still provides sufficient electrical isolation between the read and write head components. 
       FIG. 8  is a partial cross section view  800  of the thin film longitudinal head of  FIG. 7 , subsequent to heating by a thermal fly height control system (not shown), in accordance with an embodiment of the present invention. The distortion of the head due to thermal expansion effects is shown. Static dissipative layers  602 ,  506 ,  508 , and  510  extend beyond the nominal position of the ABS by a dimension D L  to protect the read and write head components from electrical discharge damage, should the head touch the media surface (not shown). The probability of such an occurrence is increased when thermal fly height control is used due the tendency to extend the relative position of sensitive read and write head structures toward the media surface, resulting from thermal expansion effects. 
       FIG. 9  is a partial, cross section view  900  of a thin film perpendicular head having embedded electrostatic dissipation layers, in accordance with an embodiment of the present invention. Layers  902 ,  904 ,  906 ,  908 , and  910  are electrostatic dissipative layers inserted within the perpendicular head structure to drain electrical charge from the storage media surface (not shown) in a controlled manner. Layers  904  and  906  protect MR read sensor  203  and shield layers  202  and  204 . Layers  908  and  910  protect write head components  216 ,  214 ,  212 , and  206 . Layers  904 ,  906 ,  908 , and  910  extend out from the ABS a dimension D P  as described in the foregoing embodiments of  FIGS. 5-8 . Layers  902 ,  904 ,  906 ,  908 , and  910  have the same material properties and compositions as the static dissipative layers described above. They are also manufactured in a manner similar to that used for longitudinal heads. 
       FIG. 10  is a partial, cross section view  1000  of a thin film perpendicular head having embedded electrostatic dissipation layers, in accordance with an embodiment of the present invention. In this embodiment, layers  902  and  904  of  FIG. 9  have been combined into layer  1002  to provide better protection from contact of the slider portion of the head assembly. 
       FIG. 11  is a partial, cross section view  1100  of a thin film perpendicular head having embedded electrostatic dissipation layers, in accordance with an embodiment of the present invention. In this embodiment, layers  906  and  908  of  FIGS. 9 ,  10  have been combined in layer  1102  to simplify the structure, reducing the number of layers. The semi-conductive properties of layer  1102  provides sufficient electrical isolation between the read and write head components. 
       FIG. 12  is a partial cross section view  1200  of the thin film perpendicular head of  FIG. 10 , subsequent to heating by a thermal fly height control system (not shown), in accordance with an embodiment of the present invention. The distortion of the head due to thermal expansion effects is shown. Static dissipative layers  1002 ,  906 ,  908 , and  910  extend beyond the nominal position of the ABS by a dimension D P  to protect the read and write head components from electrical discharge damage, should the head touch the media surface (not shown). The probability of such an occurrence is increased when thermal fly height control is used due the tendency to extend the relative position of sensitive read and write head structures toward the media surface, resulting from thermal expansion effects. 
     The present invention is not limited by the previous embodiments heretofore described. Rather, the scope of the present invention is to be defined by these descriptions taken together with the attached claims and their equivalents.