Perpendicular Magnetic Recording Transducer Sacrificial Layer Alignment
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Solution Overview
Problem
Conventional perpendicular magnetic recording (PMR) transducers face misalignment issues during fabrication, leading to increased stray edge fields and erasure of side tracks, compromising their performance.
Innovation Solution
A method involving the use of a sacrificial layer on the side gap layer, which is wet etchable and covers the side gap layer, allowing for planarization and removal of the sacrificial layer to form a wrap around shield without requiring additional masking and write gap removal, thereby reducing misalignment and stray fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional photolithography and masking steps are used to form the write gap, then the fabrication process can be completed, but misalignment occurs leading to increased stray edge fields
Solution Approach 1:
A sacrificial layer is introduced as an intermediary material between the pole and the write gap. This sacrificial layer serves as a self-aligned mask during write gap formation, eliminating the need for separate photolithography masking steps that cause misalignment. After the write gap is formed, the sacrificial layer is removed, achieving precise alignment without the harmful effects of conventional masking.
Solution Approach 2:
The sacrificial layer is deposited beforehand on the pole structure before the write gap formation process. This preliminary action creates a pre-defined pattern that automatically aligns the write gap with the pole, preventing misalignment issues that occur when masking is performed separately during the write gap formation step.
2Reliability
If the top shield is electrically connected to side shields forming a wrap around shield, then shield effectiveness is improved, but additional masking and write gap removal steps are required increasing process complexity
Solution Approach 1:
The sacrificial layer acts as a temporary intermediary structure that enables the formation of a continuous wrap-around shield. By maintaining the sacrificial layer during shield deposition, the side shields and top shield can be formed as a continuous electrical connection. The sacrificial layer is then removed, achieving the desired shield effectiveness without requiring complex additional masking and write gap removal steps.
Solution Approach 2:
The fabrication process merges the formation of side shields and top shield into a single continuous deposition step, creating a wrap-around shield structure. This combining approach eliminates the need for separate processing steps and complex masking operations, reducing fabrication complexity while maintaining shield effectiveness.
3Productivity
If conventional fabrication methods are used, then the transducer can be manufactured, but erasure of side tracks occurs due to misalignment and stray fields
Solution Approach 1:
The sacrificial layer serves as a protective intermediary during the write gap formation process. It prevents the write gap material from directly contacting the pole in misaligned regions, thereby eliminating stray edge fields that would otherwise cause erasure of side tracks. This intermediary structure enables conventional manufacturing productivity while preventing the harmful side track erasure effect.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the fabrication of PMR transducers with improved performance by reducing misalignment and stray edge fields, enhancing the transducer's ability to prevent erasure of side tracks.
Implementation Method 1
The sacrificial layer(s) are wet etched. Wet etching the sacrificial layer(s) removes the remaining portion of the sacrificial layer(s).
Data Source
AI summary
A method and system for providing a magnetic recording transducer having a pole are disclosed. The pole has side(s), a bottom, and a top wider than the bottom. The method and system include providing at least one side gap layer that covers the side(s) and the top of the pole. At least one sacrificial layer is provided on the side gap layer(s). The sacrificial layer(s) are wet etchable and cover the side gap layer(s). The magnetic recording transducer is planarized after the sacrificial layer(s) are provided. Thus, a portion of the side gap and sacrificial layer(s) is removed. A remaining portion of the sacrificial layer(s) is thus left. The method and system also include wet etching the sacrificial layer(s) to remove the remaining portion of the sacrificial layer(s). A wrap around shield is provided after the remaining portion of the sacrificial layer(s) is removed.