Gradient write gap for perpendicular magnetic recording writer

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. Pat. No. 9,042,051, filed Dec. 4, 2013, which claims the benefit of U.S. Provisional Application Ser. No. 61/866,137 filed Aug. 15, 2013, the entire contents of which are herein incorporated by reference as if fully set forth herein.

DESCRIPTION OF THE RELATED ART

Disk drives typically use heads residing on sliders to read from and write to magnetic media. Read and write transducers residing in the head are flown at a small, controlled spacing above the magnetic medium (disk) during read and write operations. An air bearing forms between the head and the disk due to the disk rotating at high speeds, which provides controlled head to disk spacing. Magnetic fields emanating from the write transducer pole tip switch magnetization of the magnetic medium, i.e., writing to the medium.

FIG. 1 illustrates a conventional disk drive 10 used for data storage. Figures are not drawn to scale and only certain structures are depicted for clarity. A disk media 50 is attached to a spindle motor and hub 20. The spindle motor and hub 20 rotate the media 50 in a direction shown by arrow 55. A head stack assembly (HSA) 60 includes a magnetic recording head 30 on an actuator arm 70 and positions the actuator arm 70 by positioning the voice coil motor (VCM) 25 over a desired data track, shown as a recording track 40 in this example, to write data onto the media 50.

FIG. 1A illustrates an enlarged view of a section of FIG. 1 including the head 30 and the track 40. A magnetic recording transducer 90 is fabricated on a slider 80. The slider 80 may be attached to a suspension 75 and the suspension 75 may be attached to the actuator arm 70 as shown in FIG. 2. The slider 80 may include a read transducer 93.

Referring again to FIG. 1A, the slider 80 is illustrated above the recording track 40. The media 50 and the track 40 are moving under the slider 80 in a down-track direction shown by arrow 42. The cross-track direction is shown by arrow 41.

The magnetic recording transducer 90 has a leading edge 91 and a trailing edge 92. In this embodiment, the trailing edge 92 of the recording transducer 90 is the final portion of the magnetic transducer 90 that writes onto the recording track 40 as the media 50 moves under the slider 80 in the down-track direction 42.

FIG. 2 illustrates a side view of the disk drive 10 shown in FIG. 1. At least one disk media 50 is mounted onto the spindle motor and hub 20. Head Disk Assembly 60 comprises at least one actuator arm 70 that carries the suspension 75 and slider 80. The slider 80 has an air bearing surface (ABS) facing the media 50. When the media 50 is rotating and the actuator arm 70 is positioned over the media 50, the slider 80 slide above the media 50 by aerodynamic pressure created between the slider ABS and the surface of media 50.

FIG. 3 illustrates a perspective view of a main pole tip section 300 of a perpendicular magnetic recording (PMR) transducer that may be implemented on the slider 80 of FIG. 2. The main pole tip section 300 has a pole tip face 310 that faces the ABS. The pole tip face 310 is illustrated in a trapezoidal shape having a trailing edge 311, a leading edge 312, a first side wall edge 313, and a second side wall edge 314. The first side wall 340 extends distally from the first side wall edge 313, the second side wall 350 (not visible, opposite first side wall 340) extends distally from the second side wall edge 314, the trailing side wall 320 extends distally from the trailing edge 311, and the leading side wall 330 (not visible, opposite trailing side wall 320) extends distally from the leading edge 312.

The main pole tip section 300 is illustrated with a trapezoidal shape at the ABS with the trailing edge 311 wider than the leading edge 312. However, other shapes may also be used. In other embodiments, for example, the side wall edge 313 and the side wall edge 314 and the corresponding side wall 340 and the side wall 350 may have facets or a curved shape; the leading edge 312 may be small, or form a point; and a trapezoid shape is not required, and may be a rectangle, or another shape having side walls. Pole surfaces and edges illustrated with straight lines may also be implemented as curved or faceted. One ordinarily skilled in the art will recognize that these shapes, combinations or variations of these shapes, and other shapes may be used.

FIG. 4 illustrates a side section view of a PMR read/write head 400 having a write transducer 450 and read sensor 410, both facing the ABS 490. The read sensor 410 may include a first shield 411 and a second shield 413 as well as a sensor 412. The write transducer 450 includes a shield 414, a main pole 401, an assist pole (or auxiliary pole) 401′, a coil 440 and a coil 440′, a leading shield 417 and a trailing shield 420. The main pole 401 has a trailing bevel 401a and a leading bevel 401b. A leading nonmagnetic gap layer 415 separates main pole 401 from underlying structures, and a trailing nonmagnetic gap layer 405 separates main pole 401 from structures above. The trailing nonmagnetic gap layer 405 is also known as a “write gap.” A non-magnetic spacer 406 may be included on a portion of the trailing bevel 401a to provide magnetic separation between the main pole 401 and the magnetic structures above. A nonmagnetic spacer layer 402 is illustrated on the non-beveled section of main pole 401; however, this nonmagnetic spacer layer 402 may be provided above main pole 401 beginning at any point distal from the ABS 490, including on the bevel 401a. A trailing seed layer 407 overlays trailing nonmagnetic gap layer 405 and spacer 406. A leading seed layer 416 is provided between leading nonmagnetic gap layer 415 and leading shield 417.

Magnetic fields emanating from the write gap switch magnetization of a magnetic medium, i.e., writing to the medium. Among other factors, a smaller and more tightly controlled magnetic writing field will allow more data to be written in the same space, thereby increasing areal density. As such, write gap characteristics play an important role in writer performance.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are provided for purposes of illustration only and merely depict typical or example implementations. These drawings are provided to facilitate the reader's understanding and shall not be considered limiting of the breadth, scope, or applicability of the disclosure. For clarity and ease of illustration, these drawings are not necessarily to scale.

FIGS. 1 and 1A illustrate a top view of a conventional hard disk drive.

FIG. 2 illustrates a side view of a conventional hard disk drive.

FIG. 3 provides a perspective view of a main pole tip section of a perpendicular magnetic recording (PMR) transducer.

FIG. 4 provides a side section view of a PMR read/write head.

FIG. 5A provides a close up side section view of a PMR writer structure having a constant width write gap.

FIG. 5B provides a close up side section view of a PMR writer having a gradient write gap, in accordance with an embodiment of the present disclosure.

FIGS. 6A and 6B provide the PMR writer structures of FIGS. 5A and 5B, respectively, with bevel angles labeled.

FIG. 7 provides an image flowchart of a first method by which a gradient write gap may be formed, in accordance with an embodiment of the present disclosure.

FIG. 8 provides an image flowchart of a second method by which a gradient write gap may be formed, in accordance with an embodiment of the present disclosure.

FIG. 9 provides an image flowchart of a third method by which a gradient write gap may be formed, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth to provide a thorough understanding of various embodiments of the present disclosure. It will be apparent, however, to one skilled in the art that these specific details need not be employed to practice various embodiments of the present disclosure. In other instances, well known components or methods have not been described in detail to avoid unnecessarily obscuring various embodiments of the present disclosure.

Perpendicular magnetic recording (PMR) writers are commonly used in today's hard drives. Write gap characteristics are an important aspect in high density PMR writers, particularly in PMR writers with linear densities beyond ˜2000 kFCI. With increasing areal densities, write gap thickness continues to scale down and is generally tightly controlled by atomic layer depositions. Writer performance is very sensitive to write gap thickness. Generally, thin write gaps will directly improve signal-to-noise ratio (SNR), but degrade the reverse overwrite (revOW). However, improvements in revOW will generally result in performance losses in wide area track erasure (WATEr), as the improved signal strength will tend to lead to increased leakage into adjacent tracks. A small distance between the main pole and high moment magnetic shield (i.e., a thin write gap) will increase the field gradient at the air bearing surface (ABS), thus improving SNR. However, thin nonmagnetic write gaps also lead to magnetic flux shunting before the flux reaching the ABS, thereby hurting the revOW.

FIG. 5A shows a PMR writer structure 510a having a write gap (WG) 512 that leads into a non-magnetic spacer 514. The end of the write gap 512 opposite the non-magnetic spacer 514 interacts with an air-bearing surface 518. In this formulation, the write gap 512 has a generally constant width. The write gap 512 and the non-magnetic spacer 514 are each composed of non-magnetic material, and together form a non-magnetic layer between the main pole 511 and the trailing shield 513. A second non-magnetic spacer 210 may also form a part of the non-magnetic layer between the main pole 511 and the trailing shield 513. The trailing shield 513 may also comprise a magnetic seed layer 515. The thin write gap 512 improves the signal-to-noise ratio of the writer 510a. However, the abrupt change in width of the write gap 512 leading into the non-magnetic spacer 514 results in magnetic flux shunting before the flux reaches the air-bearing surface 518. The presently disclosed gradient write gap addresses these issues.

A PMR writer 510b incorporating a gradient write gap (GWG), in accordance with an embodiment of the present disclosure, is presented in FIG. 5B. A gradient write gap portion 516 is added as part of the write gap 512 to gradually increase the write gap's width as it moves toward the non-magnetic spacer 514. The gradient write gap portion 516, like the write gap 512, generally comprises non-magnetic material. Examples of such non-magnetic materials may include Ru or Al₂O₃.

The PMR writer 510a in FIG. 5A has a first bevel 517 formed by the write gap 512, which leads directly into a second bevel 519 formed by the non-magnetic spacer 514. The newly added gradient write gap portion 516 in FIG. 5B creates a third bevel 521 that forms an angle that is greater than the angle formed by the first bevel 517, and smaller than that formed by the second bevel 519. In this way, a gradient is formed from the write gap 512 to the non-magnetic spacer 514.

In the structure depicted in FIG. 5B, the write gap 512 has a thin opening at the air bearing surface 518, which increases the write head's signal-to-noise ratio (SNR). However, the thickness of the gradient write gap gradually increases as it moves away from the ABS 518 towards the non-magnetic spacer 514, thereby reducing flux shunting. In this way, the benefit of an increased SNR is obtained, while simultaneously protecting against the problem of flux shunting by gradually increasing the write gap width. This can greatly improve device performance.

FIGS. 6A and 6B provide the same images of FIGS. 5A and 5B, respectively, with labeling of the relevant bevel angles so as to demonstrate the gradient write gap. In FIG. 6A, the non-magnetic layer between the main pole 511 and the shield 513, 515 is primarily defined by two bevel angles: (1) a first bevel 517 proximate the ABS 518 at a first angle 520, and (2) a second bevel 519 at a second angle 522 that is greater than the first angle 520.

In FIG. 6B, the gradient write gap portion 516 is added to the write gap 512 to create a gradient write gap. There is still the first bevel 517 at a first angle 520 (i.e., BV1A), a second bevel 519 at a second angle 522 (i.e., BV2A), and there is now an intermediate third bevel 521 at a third angle 530 (i.e., the gradient write gap angle or GWGA). The gradient write gap angle 530 creates a more gradual transition from the write gap 512 into the non-magnetic spacer 514, i.e., a gradient. As such, the gradient write gap angle 530 is greater than the first angle 520 (BV1A), and less than the second angle 522 (BV2A). Additionally, inclusion of this additional gradient write gap portion 516 to create the gradient write gap creates two different throat heights, TH1 and TH2 (as shown in FIGS. 5 and 6). The narrow opening of the write gap 512 at TH2 increases SNR, while the wider write gap opening 516 at TH1 minimizes flux shunting.

Table 1 provides data demonstrating the advantages that may be obtained by implementing the presently disclosed gradient write gap. A write head having a constant width write gap (row 1) was compared with a write head having a gradient-write gap, in accordance with an embodiment of the present disclosure (row 2). The data in the table shows that the first angle 520 (BV1A) was approximately 28 degrees, and the second angle 522 (BV2A), was approximately 65 degrees, the throat height being about 90 units. In the GWG implementation, an intermediate gradient-write gap angle 530 (GWGA) of approximately 49 degrees was created. As discussed with respect to FIG. 6, the gradient-write gap implementation results in two different throat heights. The first throat height was about 75 units, and the second throat height was about 30 units. It can be seen in Table 1, that by adding the gradient write gap, revOW increased from 30.9 to 33.3.

In certain embodiments, it may be desirable for the constant write gap width portion of the write gap, i.e., TH2, to be zero units in length. However, in practice, it should also be considered that lapping techniques for magnetic write heads are not perfectly precise, and as such, the constant write gap portion TH2 allows for a certain margin of error in the lapping process without compromising manufacturing sigmas. In any case, it should be understood that both of these situations (inclusion or removal of the constant write gap portion) are within the scope of the present disclosure.

The gradient write gap may be an added feature to current PMR writers. One process proposed to implement gradient write gaps in PMR writers is to utilize the non-magnetic spacer 514 as a hard mask for its shadowing effects. An ion-beam mill process with proper mill angle and sweep angular range will create the gradient write gap at the junction of the trailing first bevel 517 and the second bevel 519. Examples of methods for forming a gradient write gap will now be discussed in greater detail.

Exemplary method embodiments of the present invention are described below. This method may be broken down into several exemplary components:

• • regular write gap (WG) deposition
  • WG cap layer deposition: to protect the write gap from gradient-write gap (GWG) milling
  • non-magnetic spacer deposition
  • GWG material deposition: to control GWG thickness
  • GWG cap layer deposition: for mill endpoint registration
  • GWG formation by ion mill or any other appropriate method.

These components may be re-arranged in different ways to create multiple methods by which to form an exemplary gradient write gap. To provide examples of how these steps may be re-arranged, three possible methods are discussed in greater detailed here as Process Routes 1, 2, and 3, which are depicted as image flow charts in FIGS. 7, 8, and 9, respectively.

FIG. 7 provides a step-by-step breakdown of a first process route (Process Route 1) to form a gradient write gap. Process Route 1 may be summarized in the following eight steps, which are demonstrated in FIGS. 7(a)-7(f):

• • 0. BV1 process (FIG. 7(a))—This is the starting point of the process. An angled surface is formed on the main pole 750;
  • 1. WG dep—A regular write gap layer 752 is deposited on the main pole 750. One possible method for performing this step is fast ALD (atomic layer deposition). Alternative deposition methods might include physical vapor deposition or sputtering. (FIG. 7(b)). The write gap layer may comprise a non-magnetic material. Examples of such a non-magnetic material may include Al₂O₃ or Ru;
  • 2. Ru STP—A write gap stop layer 754 is deposited on the regular write gap layer 752 to protect the write gap 752 from the gradient write gap milling process, which will be discussed in greater detail in step 7. The write gap stop layer 754 may comprise Ru, Al₂O₃, Ta, amorphous carbon or similar materials;
  • 3. Spacer FALD—A non-magnetic spacer 756 is deposited on the write gap 752 and the write gap stop layer 754. Much like the write gap layer 752, the non-magnetic spacer 756 may comprise a non-magnetic material such as Ru or Al₂O₃. In a particular embodiment, the non-magnetic spacer 756 may comprise a different non-magnetic material from the write gap layer 752. For example, if the write gap layer 752 comprises Ru, then the non-magnetic spacer 756 may comprise Al₂O₃, or vice versa. In a particular embodiment, the non-magnetic spacer 756 may be deposited using fast ALD, or any other appropriate deposition method;
  • 4. BV2 RIE—A second stop layer 758 is formed on the non-magnetic spacer 756. The second stop layer 758 may comprise Ru, Al₂O₃, Ta, amorphous carbon or similar materials, and may be formed via reactive ion etch (RIE)) (FIG. 7(c));
  • 5. GWG dep—A gradient write gap (GWG) layer 760 is deposited over the write gap 752 and the non-magnetic spacer 756. This may be performed via fast ALD using a non-magnetic material, such as Ru or Al₂O₃ (FIG. 7(d));
  • 6. GWG cap—A GWG cap layer 762, which may comprise Ru, Al₂O₃, Ta, amorphous carbon or similar materials, is deposited on the GWG layer 760 (FIG. 3(d));
  • 7. GWG Mill—An ion mill is used to shape the GWG layer 760 (FIG. 3(e)). It can be seen in FIG. 7(e) that a portion of the GWG layer 760 directly above the write gap 752 has been milled away to form a more gradual, sloped shape in the GWG layer 760. The re-shaped gradient write gap layer 760 and the write gap layer 752 together form a gradient write gap. This step creates a three-bevel surface with each beveled-surface have a progressively increasing angle. A first bevel 753 is at an angle that is substantially determined by the angle of the regular write gap layer 752. A second bevel 755 is formed by the re-shaped gradient write gap layer 760, with the angle of the second bevel 755 being greater than the angle of the first bevel 753. And then a third bevel 757 extends from the second bevel 755, with the angle of the third bevel 757 substantially approximating the angle of the non-magnetic spacer 756, and being greater than the angle of the first and second bevels 753, 755.

FIG. 7(f) provides an image of an actual gradient write gap that has been formed using the Process 1 steps described above. It can be seen that the regular write gap layer 752 has a narrow opening on the left, leading to the air-bearing surface (ABS), and the GWG layer 760 creates a gradual widening of the write gap as it leads into the non-magnetic spacer 756.

FIG. 8 provides a step-by-step breakdown of a second process route (Process Route 2) that may be used to form a gradient write gap, in accordance with an embodiment of the present disclosure. Process Route 2 may be summarized in the following nine steps, as shown in FIG. 8:

• • 0. BV1 process—like Process Route 1, the process starts with a first angled surface being formed on the main pole 750;
  • 1. WG dep—Again, as in Process Route 1, a regular write gap layer 752 is deposited on the main pole 750. One possible method for performing this step is fast ALD (atomic layer deposition). Alternative deposition methods might include physical vapor deposition or sputtering (FIG. 8(a));
  • 2. Ru STP—A write gap stop layer 754 is deposited on the regular write gap layer 752 to protect the regular write gap layer 752 from the GWG milling process in step 7;
  • 3. GWG dep—This is where Process Route 2 begins to differ from Process Route 1. In Process Route 1, a non-magnetic spacer 756 was deposited on the regular write gap layer 752, and the gradient write gap layer 760 was deposited over both the regular write gap layer and the non-magnetic spacer. Here, in Process Route 2, the gradient write gap layer 760 is deposited over the write gap layer 752 before deposition of the non-magnetic spacer 756. Deposition of the gradient write gap layer 760 may be performed via fast ALD, or any other appropriate deposition method. The gradient write gap layer 760 may comprise a non-magnetic material such as Ru or Al₂O₃ (FIG. 8(c));
  • 4. GWG cap—A gradient write gap cap layer 762, which may comprise Ru, Ta, Al₂O₃, or similar non-magnetic materials, is deposited on the gradient write gap layer 760 (FIG. 8(c));
  • 5. BV2 FALD—A non-magnetic spacer 756 (i.e., BV2) is now formed on the regular write gap layer 752 and the gradient write gap layer 760 (FIG. 8(d));
  • 6. BV2 RIE—A BV2 stop layer 758 is formed on the non-magnetic spacer 756. The BV2 stop layer 758 may comprise Ru, Ta, Al₂O₃, or similar non-magnetic materials, and may be formed via reactive ion etch (RIE)) (FIG. 8(d));
  • 7. GWG Mill—An ion mill may now be used to shape the GWG layer 760 (FIG. 8(e)). It can be seen in FIG. 8(e) that a portion of the GWG layer 760 directly above the write gap 752 has been milled away to form a more gradual, sloped shape in the GWG layer 760. Once again, three contiguous beveled surfaces have been formed that progressively increase in angle: a first bevel 753 has a first angle approximating the regular write gap layer 752, a second bevel 755 has a second angle that is milled into the gradient write gap layer 760 and is greater than the first angle, and a third bevel 757 has a third angle substantially determined by the non-magnetic spacer 756, the third angle being greater than the angles of the first and second bevels 753, 755.
  • 8. Ru RIE—A final Ru cap layer 764 is formed over the re-shaped GWG layer 760. The Ru cap layer 764 may be formed via reactive ion etch using Ru, or another similar non-magnetic material.

FIG. 9 provides a step-by-step breakdown for a third process route (Process Route 3) to form a gradient write gap, in accordance with an embodiment of the present disclosure. Process Route 3 may be summarized using the following steps, as shown in FIG. 9:

• • 1. Each of the following steps have been performed in FIG. 9(a):
    • BV1 process—like Process Routes 1 and 2, the process starts with a first angled surface formed on the main pole 750;
    • Deposit BV3 stop layer—Unlike Process Routes 1 and 2, Process Route 3 includes a BV3 non-magnetic layer 770 that is deposited on the main pole 750;
    • Spacer FALD—A non-magnetic spacer 756 (i.e., BV2) is formed on the BV3 non-magnetic layer 770. The non-magnetic spacer 756 may comprise a non-magnetic material, as has been discussed previously;
    • BV2 RIE—A BV2 stop layer 758 is formed on the non-magnetic spacer 756. The BV2 stop layer 758 may comprise Ru, or other non-magnetic material, and may be formed via reactive ion etch (RIE));
  • 2. BV3 Mill—The BV3 non-magnetic layer 770 is re-shaped using an ion mill;
  • 3. WG DEP—A regular write gap layer 752 is deposited over the main pole 750, the non-magnetic spacer 756, and the BV3 non-magnetic layer 770. This may be performed using fast ALD;
  • 4. Ru STP—An write stop layer 756 is deposited on the regular write gap layer 752 (e.g., Ru or amorphous carbon or similar materials);
  • 5. GWG FALD—A gradient write gap layer 760 is deposited on the regular write gap layer 752 (e.g., fast ALD and Al2O3, etc);
  • 6. Ru CAP—A gradient write gap layer 762 is deposited on the gradient write gap 760 (e.g., Ru);
  • 7. GWG Mill—The gradient write gap layer 760 is shaped using an ion mill. This results in the formation of a first bevel 753, a second bevel 755, and a third bevel 757, similar to the end results of Processes 1 and 2 (FIGS. 7-8).
  • 8. Ru RIE—A final Ru cap layer 764 is formed over the re-shaped gradient layer 760.

In each of the processes discussed above, the regular write gap layer 752, the gradient write gap layer 760, and the non-magnetic spacer 756 together form a non-magnetic layer between the main pole 750 and a magnetic shield. As has been discussed extensively above, each of the three different process routes (FIGS. 7-9) result in the end goal of a wedge-shaped gradient write gap. The gradient write gap has a narrower write gap opening at the air-bearing surface and a gradual slope into the non-magnetic spacer 756. The gradual slope is achieved by shaping the gradient write gap layer 760 to form a bevel 755 having an angle that is greater than the angle formed by the regular write gap layer 752 and smaller than the angle formed by the non-magnetic spacer 756.

In the foregoing specification, embodiments of the disclosure have been described with reference to specific exemplary features thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the disclosure. The specification and figures are, accordingly, to be regarded in an illustrative rather than a restrictive sense. Although the disclosure has been presented with reference only to the presently preferred embodiments, those of ordinary skill in the art will appreciate that various modifications can be made without departing from this disclosure. Accordingly, this disclosure is defined only by the following claims.