Source: https://patents.google.com/patent/US8201321B2/en
Timestamp: 2020-02-20 01:16:33
Document Index: 302103119

Matched Legal Cases: ['art 100', 'art 100', 'art 91', 'art 91', 'art 91', 'art 91', 'art 91']

US8201321B2 - Method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head - Google Patents
Method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head Download PDF
US8201321B2
US8201321B2 US12/926,817 US92681710A US8201321B2 US 8201321 B2 US8201321 B2 US 8201321B2 US 92681710 A US92681710 A US 92681710A US 8201321 B2 US8201321 B2 US 8201321B2
US12/926,817
US20110086182A1 (en
2006-02-22 Priority to JP2006-45679 priority Critical
2006-02-22 Priority to JP2006045679 priority
2006-11-22 Priority to JP2006316149A priority patent/JP2007257815A/en
2006-11-22 Priority to JP2006-316149 priority
2007-02-21 Priority to US11/708,609 priority patent/US7885036B2/en
2010-12-10 Priority to US12/926,817 priority patent/US8201321B2/en
2010-12-10 Application filed by SAE Magnetics (HK) Ltd, TDK Corp filed Critical SAE Magnetics (HK) Ltd
2011-04-14 Publication of US20110086182A1 publication Critical patent/US20110086182A1/en
2012-06-19 Publication of US8201321B2 publication Critical patent/US8201321B2/en
239000010410 layers Substances 0 abstract claims description title 523
238000009740 moulding (composite fabrication) Methods 0 abstract claims description title 133
238000000231 atomic layer deposition Methods 0 claims description 40
239000010409 thin films Substances 0 description 71
-1 aluminium oxide titanium carbonate Chemical compound 0 description 5
229910001021 Ferroalloys Inorganic materials 0 description 4
229910002545 FeCoNi Inorganic materials 0 description 1
Provided is a method of manufacturing a perpendicular magnetic recording head which can enhance accuracy and simplify the manufacturing process. The method includes: forming a photoresist pattern having an opening part; forming a non-magnetic layer so as to narrow the opening part by a dry film forming method such as ALD method; stacking a seed layer and a plating layer so as to bury the opening part provided with the non-magnetic layer; and forming a main magnetic pole layer by polishing the non-magnetic layer, the seed layer, and the plating layer by CMP method until the photoresist pattern is exposed. The final opening width is unsusceptible to variations, thus reducing the number of the steps of forming the main magnetic layer.
This is a Division of application Ser. No. 11/708,609 filed Feb. 21, 2007. now U.S. Pat. No. 7,885,036 The disclosure of the prior application is hereby incorporated by reference herein in its entirety.
As an application of a magnetic device provided with a magnetic layer, a thin film magnetic head to be equipped on a magnetic recording system such as a hard disk drive is widely used in the recent years. In the field of developing the thin film magnetic head, the recording density of a magnetic recording medium such as a hard disk (hereinafter referred to simply as a “recording medium”) is far improved, and a still further improvement in performance is required, and therefore the recording system is changed from a longitudinal recording system to the perpendicular recording system. The perpendicular recording system has the advantages that a high line recording density can be obtained, and the recording medium after recording is unsusceptible to the influence of thermal fluctuation.
The thin film magnetic head of the perpendicular recording system (hereinafter referred to simply as a “perpendicular magnetic recording head”) is provided with a thin film coil generating a magnetic flux, and a magnetic pole extending from an air bearing surface to rearward, and conducting the magnetic flux to the recording medium. In the perpendicular magnetic recording head, a recording medium can be magnetized by a magnetic field for recording (a perpendicular magnetic field), and therefore information can be recorded magnetically in the recording medium.
In the field of the latest device related manufacturing, ALD (atomic layer deposition) method is used as a film forming method extremely excellent in film thickness controllability (for example, refer to “ALD atomic layer deposition system,” Techscience Ltd., Internet<URL: http://techsc.co.jp/products/mems/ALD.htm>). The ALD method is capable of forming an oxide film, a nitride film, or a metal film considerably thinly and densely under high temperature condition of 150° C. or above, and it is used in the field of manufacturing where physical characteristics such as dielectric strength is strictly required. In the field of manufacturing a thin film magnetic head, the ALD method is used in the step of forming a reproducing gap of a reproducing head (for example, refer to the specification of U.S. Pat. No. 6,759,081).
Meanwhile, the problem of so-called pole eraser is taken seriously in the recent years. The term “pole eraser” is a malfunction that, though the perpendicular magnetic recording head is in its non-recording state (non-energized state), the remaining magnetic flux in a magnetic pole performs overwriting in a recording medium thereby to unintentionally erase the information stored in the recording medium.
As used herein, the term “U-shaped cross section” means, in a restricted sense, the cross-sectional shape expressed by the contour part of the alphabet letter “U”. Here, the term “cross-sectional shape” signifies the cross-sectional shape of an instrumental die. From this, the term “U-shaped cross section” includes, in its wide sense, not only the cross-sectional shape expressed by the alphabet letter “U”, but also the cross-sectional shapes expressed by substantially letter “U” such as the alphabet letter “V” and the like.
In the second or third magnetic device or the second or third perpendicular magnetic recording head of the present invention, the first non-magnetic layer contains no inert gas, and the second non-magnetic layer contains inert gas. Whether the inert gas is present or not depends on, for example, that the first non-magnetic layer is formed by a film forming method using no inert gas, such as ALD method, and the second non-magnetic layer is formed by a film forming method using inert gas, such as sputtering method. In this case, for example, when, the film forming temperature (so-called substrate temperature) in the ALD method is lower than a general film forming temperature (about 150° C.), specifically, than the glass transition temperature of the photoresist pattern used for forming the magnetic layer or the magnetic pole, there occurs a difference in hardness between the first and second non-magnetic layers, so that the first non-magnetic layer can be recessed from the second non-magnetic layer in a direction to cross over the cross section of the first non-magnetic layer. Thus, as compared with the case where the first non-magnetic layer is not recessed from the second non-magnetic layer, the area where the first non-magnetic layer contacts with the magnetic layer or the magnetic pole can be decreased, thereby reducing the influence of the residual stress of the first non-magnetic layer to be exerted thereon. Particularly, for example, when the magnetic layer or the magnetic pole constructed of a magnetic material has tensile stress, and the first and second non-magnetic layer constructed of a non-magnetic material have compressive stress, a part of the magnetic layer or the magnetic pole which is not contacted with the first non-magnetic layer becomes a stress free state (the state being unsusceptible to the influence of the compressive stress), and therefore this part is susceptible to only the influence of tensile stress. As the result, the magnetic domain structure of the magnetic layer or the magnetic pole is hard to be fixed, and hence the initial magnetic domain structure can be maintained. These are true for the cases where the second or third magnetic device or the second or third perpendicular magnetic recording head is applied to the magnetic recording system.
In the first perpendicular magnetic recording head of the present invention, the magnetic pole may extend from an air bearing surface or its neighborhood to an area far therefrom, and an end surface of the magnetic pole on the side close to the air bearing surface may be of reverse trapezoidal shape. The term “reverse trapezoidal shape” means a trapezoidal shape whose upper bottom and lower bottom are a longer side locating on the trailing side and a shorter side locating on the leading side, respectively.
In the following description, the dimensions in X-, Y-, and Z-axis directions shown in FIGS. 1A to 5 are expressed by “width,” “length,” and “thickness or height,” respectively. In the Y-axis direction, the side close to the air bearing surface 70 and the side far therefrom are expressed by “forward” and “rearward,” respectively, and locating forward and locating rearward are expressed by “project” and “be recessed,” respectively. These are true for FIG. 6 and the succeeding figures.
The thin film magnetic head performs a magnetic process to a recording medium 80 shown in FIG. 5 (for example, a hard disk), and it is, for example, a composite head capable of performing both of recording process and reproducing process as the magnetic process. As shown in FIGS. 1A and 1B, this thin film magnetic head is comprised of, for example, an insulating layer 2, a reproducing head part 100A performing the reproducing process by using MR (magneto-resistive) effect, a separating layer 9, a recording head part 100B performing the recording process of perpendicular recording system, and an overcoat layer 21, all of which are stacked in the order named on a substrate 1. The substrate 1 is formed of a ceramic material such as aluminium oxide titanium carbonate (Al2O3.TiC). The insulating layer 2, the separating layer 9, and the overcoat layer 21 are formed of, for example, a non-magnetic insulating material such as aluminium oxide (Al2O3, hereinafter referred to simply as “alumina”).
The lower lead shield layer 3 and the upper lead shield layer 30 separate magnetically the MR element 8 from its surroundings, and extend rearward from the air bearing surface 70. For example, the lower lead shield layer 3 is formed of a magnetic material such as nickel ferroalloy (NiFe (e.g., 80 weight % of nickel and 20 weight % of iron), hereinafter referred to simply as “permalloy (product name)”). The upper lead shield layer 30 is comprised of two upper lead shield layer portions 5 and 7, which are stacked with a non-magnetic layer 6 interposed therebetween. Each of the upper lead shield layer portion 5 and 7 is formed of a magnetic material such as “permalloy.” The non-magnetic layer 6 is formed of a non-magnetic material such as ruthenium (Ru) or alumina. The upper lead shield layer 30 is not necessarily required to have a stacked structure, and it may have a single-layer structure.
The positional relationship between the main magnetic pole layer 40 and the non-magnetic layers 12 and 15 in the vicinity of the air bearing surface 70 is, for example, as shown in FIG. 4. An end surface 15M of the non-magnetic layer 15 on the side close to the air bearing surface 70 is located on the air bearing surface 70, whereas an end surface 12M of the non-magnetic layer 12 on the side close to the air bearing surface 70 is not located on the air bearing surface 70. That is, the non-magnetic layer 12 is recessed from the non-magnetic layer 15 in the direction to cross over the cross section of the non-magnetic layer 12. A recessing distance L1 of the non-magnetic layer 12 (a distance between the air bearing surface 70 and the front end of the non-magnetic layer 12) can be set arbitrarily. As an example, it is about a several nm. Like the end surface 15M of the non-magnetic layer 15, the end surface 40M of the main magnetic pole layer 40 is located on the air bearing surface 70. That is, the main magnetic pole layer 40 projects from the non-magnetic layer 12. The positional relationship between the main magnetic pole layer 40 and the non-magnetic layers 12, can be specified by using surface observation means such as atomic force microscope (AFM).
The upward arrows shown in FIGS. 1A and 1B, and FIG. 5 indicate an advance direction M in which the recording medium 80 moves relatively to the thin film magnetic head. The above-mentioned “trailing side” means, when the state of the recording medium 80 moving in the advance direction M is regarded as a flow, the side on which the flow runs out (the forward side in the advance direction M), namely the upper side in the thickness direction (the Z-axis direction) in this case. On the other hand, the side on which the flow runs in (the rear side in the advance direction M) is referred to as “leading side,” namely the lower side in the thickness direction in this case. The upper edge E1 as the recording point in the main magnetic pole layer 40 is referred to as trailing edge TE, and its width W1 is referred to as trailing edge width.
First of all, the outline of the manufacturing process of the entire thin film magnetic head will be described with reference to FIGS. 1A and 1B, then the process of forming a key part to which applied is a method of manufacturing the perpendicular magnetic recording head according to the preferred embodiment of the present invention will be described with reference to FIGS. 1A and 1B to FIG. 13A to 13B. Since the materials, dimensions, and structures of a series of components constituting the thin film magnetic head have already been described in detail, the descriptions corresponding to these will be omitted in the following. Since a method of forming a magnetic layer pattern of the present invention is applied to a method of manufacturing a perpendicular magnetic recording head as an example, the method of forming a magnetic layer pattern will be described together in the following.
Subsequently, as shown in FIG. 7, a non-magnetic layer 12 is formed so as to narrow the opening part 91K by covering at least the inner wall 91W of the photoresist pattern 91 in the opening part 91K by using dry film forming method. When forming the non-magnetic layer 12, for example, ALD method is used to cover the surface of the photoresist pattern 91 (including the inner wall 91W) and the exposed surface of the non-magnetic layer 11 in the opening part 91K. In this case, it is particularly controlled so that the film forming temperature (so-called substrate temperature) of the ALD method is lower than the deformation temperature (the glass transition temperature) of the photoresist pattern 91. By using the ALD method, the inner wall 91W can be covered with the non-magnetic layer 12 of a uniform thickness, and hence the inclination Φ of the inner wall 12W of the non-magnetic layer 12 corresponding to the inner wall 91W (the angle formed between the inner wall 12W and the surface of the non-magnetic layer 11) can be equal to an inclination ω.
With the method other than the ALD method, when a non-magnetic layer 12 is formed so as to cover an inner wall 91W of a photoresist pattern 91 as shown in FIG. 15, the thickness of the non-magnetic layer 12 may be changed along the inner wall 91W depending on the depth or the inclination ω of an opening part 91K, and therefore the inclination Φ might deviate from the inclination ω. As an example of the change of the thickness, it can be assumed, for example, that the thickness of the non-magnetic layer 12 is gradually increased as it is spaced apart from the non-magnetic layer 11. In this case, the bevel angle θ deviates from the inclination ω, as shown in FIG. 16, and therefore, the trailing edge width W1 and the bevel angle θ may deviate from desired values, respectively. Although the accuracy of determining the trailing edge width W1 and the bevel angle θ can be higher than that in the related art, it might not be sufficient under the manufacturing specification requiring a strict accuracy.
The followings are the technical significances of the use of the ALD method in the present invention. Generally, in the field of forming an insulating layer where physical characteristic such as dielectric strength is strictly required, the film forming temperature of the ALD method is set to a high temperature of about 150° C. or above in order to suppress the possibility of occurrence of pinholes, with regard for film compactness. This temperature condition is set for the purpose of sufficiently increasing film compactness according to the required physical characteristic. On the other hand, the present invention calls for only the film thickness controllability of the non-magnetic layer 12 in order to narrow the opening part 91K, while controlling the inclination Φ to be equal to the inclination ω, as shown in FIG. 7. Hence, the film forming temperature of the ALD method is set to be lower than the above-mentioned general film forming temperature (about 150° C. or above). That is, setting the film forming temperature to somewhat a low value may cause no problem because the intended use of the non-magnetic film 12 requires only sufficient film thickness controllability, even if film compactness is somewhat low. More specifically, though the film compactness of the non-magnetic layer 12 will be lowered by setting the film forming temperature to a low value, it goes without saying that the non-magnetic layer 12 can have film compactness within a practically permissible range as long as the ALD method is used. Hence, the present invention is significant in the point of setting the film forming temperature of the ALD method to a lower value than the general film forming temperature, in order to control the trailing edge width W1 and the bevel angle θ.
In the present embodiment, the main magnetic pole layer 40 is formed so as to have the sectional shape of the reverse trapezoidal shape as shown in FIG. 10, by forming the photoresist pattern 91 so that the inner wall 91W is inclined to the surface of the non-magnetic layer 11 (an inclination ω<90°), as shown in FIG. 6. Without limiting to this, for example, the main magnetic pole layer 40 may be formed so as to have a rectangular sectional shape as shown in FIG. 22 corresponding to FIG. 10, by forming the photoresist pattern 91 so that the inner wall 91W is orthogonal to the surface of the non-magnetic layer 11 (an inclination ω=90°), as shown in FIG. 21 corresponding to FIG. 6. This also provides the same effect.
Firstly, as a representative of the above-mentioned series of perpendicular magnetic recording heads, the surface structure of the perpendicular magnetic recording head shown in FIG. 17 was observed, and the result shown in FIG. 26 was obtained. FIG. 26 shows the surface structure in the vicinity of the air bearing surface 70 observed on an AFM, on which the abscissa and the ordinate represent position and height in a track width direction, respectively. The term “position in the track width direction” means the position in the X-axis direction shown in FIG. 17. In the observation of the surface structure, there were used alumina as the material for forming the non-magnetic layers 12 and 15, iron cobalt alloy (FeCo) as the material for forming the seed layer 13, and iron nickel alloy (FeNi) as the material for forming the plating layer 14, respectively. There were used ALD method as the method of forming the non-magnetic layer 12, and sputtering method as the method of forming the non-magnetic layer 15, respectively.
As shown in FIG. 26, on the surface in the vicinity of the air bearing surface 70, a region R1 far forming the non-magnetic layer 15 is substantially flat, whereas a region R2 for forming a non-magnetic layer 12 is recessed, and a region R3 for forming the main magnetic pole layer 40 is projected. This result shows that, though both of the non-magnetic layers 12 and 15 are formed of a hard oxide, the non-magnetic layer 15 formed by the sputtering method constitutes part of the air bearing surface 70, and the non-magnetic layer 12 formed by the ALD method is recessed from the air bearing surface 70, whereas the main magnetic pole layer 40 projects from the air bearing surface 70 because it is formed of a soft alloy. This verified that in the present invention the non-magnetic layer 12 can be retreated from the non-magnetic layer 15 after forming the air bearing surface 70, by forming the non-magnetic layer 12 with the ALD method and the non-magnetic layer 15 with the sputtering method.
Next, the trailing edge width of the main magnetic pole layer 40 formed by the above-mentioned method of manufacturing a perpendicular magnetic recording head was checked, and the result shown in FIG. 27 was obtained. FIG. 27 shows the correlation between the thickness of the non-magnetic layer 12 and the trailing edge width, on which the abscissa and the ordinate represent the thickness T (μm) of the non-magnetic layer 12 and the trailing edge width W (μm), respectively. In checking this correlation, the same materials as described in respect to FIG. 26 were used as the materials for forming the non-magnetic layer 12 and the main magnetic pole layer 40, and the trailing edge width W was determined by observing the cross section of the main magnetic pole layer 40 with FIB (focused ion beam etching) method. When forming the non-magnetic layer 12, the film forming temperature was set to 90° C. so as to be lower than the glass transition temperature of the photoresist pattern 91, and the thickness T was changed through three stages (0.024 μm, 0.05 μm, and 0.07 μm).
1. A method of forming a magnetic layer pattern comprising:
forming on a base a photoresist pattern having an opening part;
forming, by an atomic layer deposition (ALD) method, a first non-magnetic layer so as to narrow the opening part by covering at least an inner wall of the photoresist pattern in the opening part;
forming a magnetic layer so as to fill at least the opening part provided with the first non-magnetic layer; and
forming a magnetic layer pattern at the opening part by selectively removing at least a portion of the first non-magnetic layer and at least a portion of the magnetic layer until at least a portion of the photoresist pattern is exposed.
2. The method of forming a magnetic layer pattern according to claim 1, wherein a film forming temperature in the ALD method for forming the first non-magnetic layer is controlled to be lower than a glass-transition temperature of the photoresist pattern.
3. The method of forming a magnetic layer pattern according to claim 1, wherein in forming the magnetic layer pattern, the at least a portion of the first non-magnetic layer and the at least a portion of the magnetic layer are removed by polishing.
4. The method of forming a magnetic layer pattern according to claim 1, further comprising:
removing the photoresist pattern remaining;
forming a second non-magnetic layer so as to cover the first non-magnetic layer and the magnetic layer pattern; and
selectively removing at least a portion of the second non-magnetic layer until at least a portion of the first non-magnetic layer and at least a portion of the magnetic layer pattern are exposed.
5. The method of forming a magnetic layer pattern according to claim 1, wherein the magnetic layer is formed by forming a seed layer on the first non-magnetic layer, and thereafter growing a plating layer on the seed layer.
6. A method of manufacturing a perpendicular magnetic recording head comprising:
forming a magnetic pole at the opening part by selectively removing at least a portion of the first non-magnetic layer and at least a portion of the magnetic layer until at least a portion of the photoresist pattern is exposed.
7. The method of manufacturing a perpendicular magnetic recording head according to claim 6, wherein a film forming temperature in the ALD method for forming the first non-magnetic layer is controlled to be lower than a glass transition temperature of the photoresist pattern.
8. The method of manufacturing a perpendicular magnetic recording head according to claim 6, wherein in forming the magnetic pole, the at least a portion of the first non-magnetic layer and the at least a portion of the magnetic layer are removed by polishing.
9. The method of manufacturing a perpendicular magnetic recording head according to claim 6, further comprising:
forming a second non-magnetic layer so as to cover the first non-magnetic layer and the magnetic pole; and
selectively removing at least a portion of the second non-magnetic layer until at least a portion of the first non-magnetic layer and at least a portion of the magnetic pole are exposed.
10. The method of manufacturing a perpendicular magnetic recording head according to claim 6, wherein the magnetic layer is formed by forming a seed layer on the first non-magnetic layer, and thereafter growing a plating layer on the seed layer.
US12/926,817 2006-02-22 2010-12-10 Method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head Active US8201321B2 (en)
JP2006-45679 2006-02-22
JP2006045679 2006-02-22
JP2006316149A JP2007257815A (en) 2006-02-22 2006-11-22 Magnetic device, perpendicular magnetic recording head, magnetic recording device, method of forming magnetic layer pattern , and method of manufacturing perpendicular magnetic recording head
JP2006-316149 2006-11-22
US11/708,609 US7885036B2 (en) 2006-02-22 2007-02-21 Magnetic device, perpendicular magnetic recording head, magnetic recording system, method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head
US12/926,817 US8201321B2 (en) 2006-02-22 2010-12-10 Method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head
US11/708,609 Division US7885036B2 (en) 2006-02-22 2007-02-21 Magnetic device, perpendicular magnetic recording head, magnetic recording system, method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head
US20110086182A1 US20110086182A1 (en) 2011-04-14
US8201321B2 true US8201321B2 (en) 2012-06-19
ID=38427941
US11/708,609 Active 2029-09-19 US7885036B2 (en) 2006-02-22 2007-02-21 Magnetic device, perpendicular magnetic recording head, magnetic recording system, method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head
US12/926,817 Active US8201321B2 (en) 2006-02-22 2010-12-10 Method of forming magnetic layer pattern, and method of manufacturing perpendicular magnetic recording head
US (2) US7885036B2 (en)
JP (1) JP2007257815A (en)
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2010-12-10 US US12/926,817 patent/US8201321B2/en active Active
ALD Atomic Layer Deposition System; Internet website of Techscience Ltd. (www.techsc.co.jp); pp. 1-3; with partial translation.
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