Thin film head reader with lead overlay a method of fabrication thereof

Abstract

A magnetoresistive sensor having a well defined track width and method of manufacture thereof.

What is claimed is:  
     
         1 . A magnetic head, comprising: 
 a magnetoresistive layer, having a central active region and first and second laterally opposed end regions terminating in first and second sides;    first and second electrically conductive pads overlaying said magnetoresistive layer at said first and second end regions and terminating at said first and second sides;    first and second hard bias layers contacting said first and second sides; and    first and second electrically conductive lead layers overlaying at least a portion of said first and second electrically conductive pads.    
     
     
         2 . A magnetic head as set forth in  claim 1  and wherein said and first and second electrically conductive pads comprise Rh.  
     
     
         3 . A magnetic head as set forth in  claim 1  wherein the first and second lead layers comprise Rh.  
     
     
         4  A magnetic head as set forth in  claim 1  wherein said magnetoresistive sensor has a substantially flat surface that is bounded by said first and second laterally opposed sides and wherein said first and second electrically conductive pads prevent said first and second hard bias layers from contacting said substantially flat surface.  
     
     
         5 . A magnetic head, comprising, 
 a magnetoresistive element having a substantially flat surface and laterally opposed first and second side portions;    said first and second side portions joining said flat surface to form first and second edges;    first and second electrically conductive pads contacting said substantially flat surface and terminating at said first and second edges respectively; and    first and second hard magnetic biasing layers disposed adjacent to said first and second side portions.    
     
     
         6 . A magnetic head as recited in  claim 6  wherein said first and second electrically conductive pads prevent contact between said first and second hard magnetic biasing layers and said substantially flat surface.  
     
     
         7 . A magnetic sensor as set forth in  claim 5  further comprising first and second electrically conductive leads contacting said first and second electrically conductive pads.  
     
     
         8 . A magnetic sensor as set forth in  claim 7  wherein said first and second electrically conductive pads are relatively thin as compared with said first and second electrically conductive lead.  
     
     
         9 . A method of constructing a magnetic sensor, comprising the steps of: 
 depositing a layer of magnetoresistive sensor material;    forming a first electrically conductive layer having a gap, the width of said gap defining a track width;    depositing a mask layer, said mask layer shielding said gap and a portion of said electrically conductive layer adjacent to said gap; and    performing a material removal process to remove exposed portions of said electrically conductive layer and said magnetoresistive sensor material.    
     
     
         10 . A method as recited in  claim 9  further comprising the step of, depositing a layer of magnetic material prior to removing said mask.  
     
     
         11 . A method as recited in  claim 9  wherein said material removal process is reactive on etching.  
     
     
         12 . A method as recited in  claim 9  wherein said material removal process is ion milling.  
     
     
         13 . A method of manufacturing a magnetic head, comprising: 
 providing a substrate;    depositing a magnetoresistive material layer;    forming a first mask on the magnetoresistive material layer;    depositing a first electrically conductive material;    removing said first mask;    forming a second mask, the second mask being wider than the first mask;    performing a material removal procedure to remove material not protected by said second mask;    depositing a hard magnetic material;    depositing a second electrically conductive material; and    removing said second mask.    
     
     
         14 . A method of manufacturing a magnetic head, comprising: 
 providing a substrate;    depositing a magnetoresistive material onto said substrate;    depositing a first electrically conductive material;    forming a first mask on said first electrically conductive material, said mask having an opening to expose a portion of said first electrically conductive material;    performing a first material removal process to remove electrically conductive material exposed by said mask to form a gap in said electrically conductive material;    removing said first mask;    forming a second mask, the second mask being wider than said first mask;    performing a second material removal process to remove material not protected by said second mask;    depositing a hard magnetic material;    depositing a second electrically conductive material; and    removing said second mask.    
     
     
         15 . A magnetic disk drive, comprising: 
 a chassis;    motor coupled with said chassis;    spindle rotateably coupled with said motor;    a disk coupled with said spindle for rotation thereabout;    an actuator pivotally coupled with said chassis;    a slider coupled with an end of said actuator for arcuate movement across a surface of said disk;    a magnetic write element coupled with said slider; and    a magnetic read element coupled with said slider, said read element further comprising: 
 a magnetoresistive layer, having a central active region and first and second laterally opposed end regions terminating in first and second sides;  
 first and second electrically conductive pads overlaying said magnetoresitive layer at said first and second end regions and terminating at said first and second sides;  
 first and second hard bias layers contacting said first and second sides; and  
 first and second electrically conductive lead layers overlaying at least a portion of said first and second electrically conductive pads.  
   
     
     
         16 . A magnetic head as recited in  claim 1  wherein said first and second electrically conductive pads are 20-30 manometers.