Perpendicular Write Head Stepped Flare Structure
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Solution Overview
Problem
Current manufacturing processes are unable to accurately control the flare point and trailing shield throat height in magnetic write heads, limiting the miniaturization of write head sizes and subsequent data capacity in perpendicular magnetic recording systems.
Innovation Solution
A magnetic write head design featuring a secondary flare point defined by a stepped magnetic shell structure and a non-magnetic spacer, allowing for precise control of the flare point location and throat height using existing photolithographic tools and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used, then existing tools and processes can be utilized, but the flare point and trailing shield throat height cannot be accurately controlled
Solution Approach 1:
The magnetic shell structure is segmented into multiple portions with different thicknesses, creating a stepped configuration. This segmentation allows the flare point to be defined by a specific step interface rather than requiring precise control of a continuous structure, thereby improving manufacturing precision while maintaining ease of manufacture through standard photolithographic processes.
Solution Approach 2:
The invention transitions from controlling flare point position in a single dimension to defining it through a stepped structure in multiple dimensions. The magnetic shell has varying thicknesses (first, second, and third portions) that create discrete steps, allowing the flare point to be precisely located at a step interface. This multi-dimensional approach enables accurate flare point control using existing photolithographic tools without significantly increasing manufacturing complexity.
2Productivity
If write head size is reduced to increase data capacity, then data storage capacity improves, but control of flare point and throat height becomes more difficult
Solution Approach 1:
The magnetic shell is divided into discrete thickness segments (first, second, and third portions) that form steps. This segmentation creates well-defined interfaces that can be precisely controlled during manufacturing. By defining the flare point at a step interface rather than requiring continuous dimensional control, the invention achieves high manufacturing precision even as write head size is reduced to increase data capacity.
Solution Approach 2:
The invention changes the geometric parameters of the magnetic shell by introducing discrete thickness steps rather than continuous variations. The magnetic shell has a first portion with a first thickness, a second portion with a second thickness, and a third portion with a third thickness, creating stepped interfaces. This parameter discretization enables precise control of the flare point location and throat height, allowing write head miniaturization for higher data capacity while maintaining manufacturing precision.
3Manufacturing precision
If a stepped magnetic shell structure is used, then flare point control precision is improved, but device structure becomes more complex
Solution Approach 1:
The magnetic shell structure is segmented into multiple portions with different thicknesses, creating a stepped configuration. This segmentation allows the flare point to be defined by a specific step interface rather than requiring precise control of a continuous structure. While the structure is divided into segments, each segment can be formed using standard photolithographic processes, so the overall device complexity increase is minimal while achieving improved flare point location control.
Solution Approach 2:
The magnetic shell's geometric parameters are changed by introducing discrete thickness steps. The structure includes a first portion with a first thickness, a second portion with a second thickness, and a third portion with a third thickness, creating stepped interfaces that define the flare point. This parameter discretization improves flare point location control precision. The complexity increase is manageable because the stepped structure can be formed using existing photolithographic tools without requiring entirely new manufacturing techniques.
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
Enables the construction of write heads with tightly controlled flare points and throat heights, facilitating the reduction of write head sizes and enhancing data storage capacity.
Implementation Method 1
The magnetic shell structure has an end surface that forms a stepped feature that defines a secondary flare point
Implementation Method 2
A non-magnetic spacer is formed over the magnetic shell structure to provide additional spacing between a trailing magnetic shield and the magnetic shell portion
Implementation Method 3
Current conducted to the coil layer induces a magnetic flux in the pole pieces which causes a magnetic field to fringe out at a write gap at the ABS for the purpose of writing the aforementioned magnetic transitions
Implementation Method 4
a spin valve sensor, also referred to as a giant magnetoresistive (GMR) sensor, is employed for sensing magnetic fields from the rotating magnetic disk
Data Source
AI summary
A magnetic write head for data recording having a magnetic write pole with a stepped magnetic shell structure that defines a secondary flare point. The secondary flare point defined by the magnetic shell portion can be more tightly controlled with respect to its distance from the air bearing surface (ABS) of the write head than can a traditional flare point that is photolithographically on the main pole structure. This allows the effective flare point of the write head to be moved much closer to the ABS than would otherwise be possible using currently available tooling and photolithography techniques. The write head also includes a non-magnetic spacer layer formed over the magnetic shell structure that is recessed from the ABS by a distance that is greater than that of the magnetic shell portion. A magnetic shield is formed over the magnetic shell and non-magnetic spacer.