Patent ID: 7016165

Claim:
A method for forming a spin-valve type abutted junction GMR sensor element with a thinner hard magnetic longitudinal bias layer having significantly improved magnetic properties in the junction region comprising: providing a substrate; forming over said substrate a first seed layer for said spin-valve GMR sensor element; forming over said first seed layer said spin-valve GMR sensor element; etching said spin-valve GMR sensor element and said first seed layer to produce surfaces for abutted junctions, said surfaces including substantially vertical lateral edge surfaces on said sensor element and horizontal projections on said first seed layer; forming over said surfaces for abutted junctions a lattice matching second seed layer for said hard magnetic longitudinal bias layer, said second seed layer covering all of said surfaces; forming over said lattice matching seed layer said hard magnetic longitudinal bias layer, an undersurface of said bias layer contacting only the second seed layer; forming over said hard magnetic longitudinal bias layer a conducting lead layer.