US20010012177A1 - Advanced writer for chip-on-load beam - Google Patents

Abstract

A write element for recording data on a magnetic medium is provided having an impedance designed to substantially match the impedance of an electrical interconnection between it and a pre-amp chip located nearby on the load beam. Additional embodiments are directed to incorporating a read element with the write element to form a read/write head, and to further incorporate the read/write head into a magnetic disk drive. Further embodiments are directed towards the fabrication of the write element.

Description

BACKGROUND OF THE INVENTION
• This invention relates generally to magnetic data storage systems, more particularly to thin film read/write heads, and most particularly to a write element with an impedance tailored to be able to match the impedance of a shorten connector between a pre-amp chip and the write element, allowing for both higher data transfer rates and higher storage capacities.[0001]
• Magnetic disk drives are used to store and retrieve data for digital electronic apparatuses such as computers. In FIGS. 1A and 1B, a magnetic disk[0002]data storage system10 includes a sealedenclosure12, adisk drive motor14, and a magnetic disk, or media,16 supported for rotation by a drive spindle S1 ofmotor14. Also included are anactuator18 and anarm20 attached to an actuator spindle S2 ofactuator18. Asuspension22 is coupled at one end to thearm20, and at its other end to a read/write head or transducer24. Thetransducer24 typically includes an inductive write element with a sensor read element (which will be described in greater detail with reference to FIG. 2). As themotor14 rotates themagnetic disk16, as indicated by the arrow R, an air bearing is formed under thetransducer24 causing it to lift slightly off of the surface of themagnetic disk16, or, as it is sometimes termed in the art, to “fly” above themagnetic disk16. Data bits can be written to and read from a magnetic “track” as themagnetic disk16 rotates. Also, information from various tracks can be read from themagnetic disk16 as theactuator18 causes thetransducer24 to pivot in an arc as indicated by the arrows P. The width of a track is sometimes called the “trackwidth.” Narrower trackwidths allow a greater number of tracks to be placed on amagnetic disk16, thereby increasing its total storage capacity. The design and manufacture of magnetic disk data storage systems is well known to those skilled in the art.
• FIG. 2 depicts a magnetic read/write[0003]head24 of the prior art including aread element26 and awrite element28. Surfaces of theread element26 and writeelement28 also define a portion of an air bearing surface ABS, in aplane29, which can be aligned to face the surface of the magnetic disk16 (see FIGS. 1A and 1B). Theread element26 includes afirst shield30, anintermediate layer32, which functions as a second shield, and aread sensor34 that is located within adielectric medium35 between thefirst shield30 and thesecond shield32. The most common type ofread sensor34 used in the read/writehead24 is the magnetoresistive (AMR or GMR) sensor which is used to detect magnetic field signals from a magnetic medium through changing resistance in the read sensor.
• The[0004]write element28 is typically an inductive write element which includes afirst pole38 and theintermediate layer32, which functions as a second pole. Asecond pole pedestal42 is connected to a second pole tip portion45 of the second pole. Thefirst pole38 and thesecond pole32 are attached to each other by abackgap portion40, with these three elements collectively forming a yoke41 with thesecond pole pedestal42. The area around the first pole tip portion43 and a second pole tip portion45 near the ABS is sometimes referred to as theyoke tip region46. Awrite gap36 is formed between thefirst pole38 and thesecond pole pedestal42 in theyoke tip region46, and is formed from a non-magnetic electrically insulating material. This non-magnetic material can be either integral with or separate from (as shown here) afirst insulation layer47 that lies between thefirst pole38 and thesecond pole32, and extends from theyoke tip region46 to thebackgap portion40.
• Also included in write[0005]element28 is aconductive coil layer48, formed ofmultiple winds49. Theconductive coil48 is positioned within acoil insulation layer50 that lies below thefirst pole38. Thecoil insulation layer50 thereby electrically insulates thecoil layer48 from thefirst pole38 and insulates themultiple winds49 from each other, while thefirst insulation layer47 electrically insulates thewinds49 from thesecond pole32.
• An inductive write head such as that shown in FIG. 2 operates by passing a writing current through the[0006]conductive coil layer48. Because of the magnetic properties of the yoke41, a magnetic flux can be induced in the first andsecond poles38 and32 by a write current passed through thecoil layer48. Thewrite gap36 allows the magnetic flux to fringe out from the yoke41 (thus forming a fringing gap field) and to cross a magnetic recording medium that is placed proximate the ABS.
• FIG. 3 shows an alternative[0007]magnetic write element25 of the prior art including twoconductive coil layers60 and62. The overall structure ofmagnetic write element25 is similar to writeelement28 and includes afirst pole38, asecond pole32, abackgap40, asecond pole pedestal42, awrite gap36, and afirst insulation layer47. The primary differences between this prior art writeelement25 and writeelement28 of FIG. 2 is the additionalwrite gap layer27 of which thewrite gap36 is part, and the arrangement of twostacked coil layers60 and62 rather than asingle coil layer48.
• In write[0008]element25 thewrite gap layer27 may be formed of a non-magnetic electrically insulating material disposed above thefirst insulation layer47. Afirst coil layer60 is formed of firstmultiple winds64 disposed above thewrite gap layer27. The firstmultiple winds64 are insulated from one another, and covered by, asecond insulation layer65. Asecond coil layer62 is formed of secondmultiple winds66 disposed above thesecond insulation layer65. The second multiple winds are insulated from one another, and covered by, athird insulation layer67. The firstmultiple winds64 and the secondmultiple winds66 are both formed of electrically conductive materials. The secondinsulating layer65 and the thirdinsulating layer67 are both formed from non-magnetic electrically insulating materials. The secondinsulating layer65 insulates thefirst coil layer60 from thefirst pole38 and from thesecond coil layer62. The thirdinsulating layer67 insulates thesecond coil layer62 from thefirst pole38.
• The[0009]write element25 with twocoil layers60 and62 has certain advantages over thewrite element28 with onecoil layer48. Stacking multiple coil layers permits writeelement25 to be more compact, shortening the distance from thebackgap40 to thesecond pole pedestal42, a distance sometimes referred to as the yoke length YL. A shorter yoke length permits a shorter flux rise time, the length of time necessary for the fringing gap field across thewrite gap36 to rise to its maximum intensity from its minimum intensity when an electric current is passed through the coil winds. The rate at which data may be written to amagnetic disk16 increases as the flux rise time decreases. Therefore, a shorter yoke length allows higher data recording rates to be achieved.
• Unfortunately, stacking multiple coil layers in a write element can be a disadvantage as well. Multiple coil layers can increase another parameter, sometimes referred to as the stack height SH, the distance between the top surface of the[0010]first pole38 and the top of thesecond pole32. The increased topography of the write element created by a larger stack height can make the formation of thefirst pole38 more difficult, leading to both decreased performance and lower yields.
• FIG. 4 shows a head gimbal assembly (HGA) according to the prior art. The head gimbal assembly includes a[0011]base21 attached to aload beam23. Theload beam23 includes anarm20 attached between thebase21 and asuspension22. Thesuspension22 is attached to thearm20 at a first end and is attached to a read/writehead24 at an opposite end. Apre-amp chip142 is attached to thebase21. Thepre-amp chip142 is electrically connected to the read/writehead24 by ametallic interconnection144 such as copper traces or wires. Themetallic interconnection144 carries electrical signals between thepre-amp chip142 and the read/writehead24. In addition, thepre-amp chip142 is connected to acontroller connector146 which can electrically connect the pre-amp chip to a controller (not shown). Thus, the pre amp-chip142 is also configured to pass electric signals to and from the controller.
• The pre-amp[0012]chip142 is located on thebase21 to place it close to the read/writehead24. Shortening the distance between thepre-amp chip142 and the read/writehead24 allows for a higher circuit resonant frequency, in turn allowing for higher data transfer rates. However, it is also necessary to match the impedance of themetallic interconnection144 with the impedance of the read/writehead24 as failure to do so may degrade the signal. To match the impedance of prior art read/writeheads24, ametallic interconnection144 of the prior art has had to be sufficiently long, as impedance in a conductor increases as a function of its length. Consequently, this has necessitated placing thepre-amp chip142 further away from the read/writehead24 than would otherwise be desirable.
• Thus, what is desired is a write element with a lower impedance that would allow a pre-amp chip to be located nearer to the write element and preferably on the load beam itself. Further, it is desired that fabrication of such a write element, and a read/write head incorporating the same, be inexpensive, quick, and simple.[0013]
SUMMARY OF THE INVENTION
• The present invention provides a magnetic recording device and method for making the same having a specifically tailored impedance to allow for a pre-amp chip to be located on the load beam nearer to the recording device than previously possible.[0014]
• In an embodiment of the present invention a recording device for recording data on a magnetic medium comprises a yoke, a write gap layer, two coil layers, and three insulation layers. The yoke, having a characteristic yoke length, comprises a first pole, a second pole, a backgap portion, and a first pole pedestal, each formed of ferromagnetic materials. The first and second poles each have a pole tip portion aligned with one another. Both poles are magnetically connected by way of the backgap portion, located distal their respective pole tip portions. The first pole pedestal is magnetically connected to, and aligned with, the first pole tip portion. Another embodiment is directed towards incorporating into the yoke a second pole pedestal, also formed of a ferromagnetic material, and situated between the write gap layer and the second pole.[0015]
• The yoke forms a discontinuous ring with a single gap. Within the interior space defined by the yoke are a write gap layer, two coil layers, and three insulation layers. The write gap layer extends from the write gap region, the space between the first pole pedestal and the second pole tip portion, to the distal end of the second pole, and separates the turns of the first coil layer from the turns of the second coil layer. A first pole insulation layer insulates the first pole from the turns of the first coil layer, and a first coil insulation layer disposed between the turns of the first coil layer insulates those turns from one another. A second coil insulation layer insulates the turns of the second coil layer from each other and from the second pole. The write gap layer and each of the insulation layers may be formed of suitable non-magnetic and electrically insulating materials, while the turns of the two coil layers may be formed of electrically conductive materials. At a minimum, each coil layer has at least one turn.[0016]
• This structure is advantageous because it allows for a shorter yoke length that reduces the device's flux rise time, thus, allowing for higher data recording rates. The placement of the write gap layer is also advantageous in this design because it limits the height of the first coil layer, thereby reducing the overall stack height of the device. Reducing the stack height facilitates the formation of the second pole.[0017]
• Another embodiment of the present invention is a data transfer device for exchanging data with a magnetic medium comprising a load beam to which a recording device and a pre-amp chip are attached. The recording device is configured according to the embodiments previously described. The pre-amp chip is electrically connected to the recording device, and is connectable to a controller. The pre-amp chip is intended to pass electrical signals to and from both the controller and the recording device. Yet another embodiment is directed to locating the pre-amp chip at a sufficient distance from the recording device such that the impedance of the recording device and the impedance of a connector between the recording device and the pre-amp chip are substantially equal. Minimizing the impedance mismatch between the connector and the recording device while locating the pre-amp chip closer to the recording device is advantageous for decreasing the current rise time and the flux rise time, allowing for higher data transfer rates.[0018]
• Still other embodiments include a read element, also connected to the pre-amp chip. Such a read element may include two shields and a read sensor, where the read sensor is disposed between a first shield and the first pole of the recording device configured to act as a second shield. Yet other embodiments additionally include a medium support and a read/write head support system. The medium support may further include a spindle on which the magnetic medium can be supported, and a medium motor capable of rotating the magnetic medium around the axis of the spindle. The read/write head support system further includes the load beam and pre-amp chip, and is intended to suspend the read/write head proximate to the magnetic medium.[0019]
• In yet another embodiment of the present invention, a method for forming a recording device includes providing a first pole having a pole tip portion. The first pole is substantially planarized prior to forming a first pole pedestal above and magnetically connected to the first pole at its pole tip portion. A backgap portion is formed above and magnetically connected to the first pole distal to its pole tip portion. A first pole insulation material is deposited over the first pole pedestal, first pole, and backgap portion and a first pre-coil layer is formed above the first pole insulation layer. A first coil insulation layer is deposited over the first pre-coil layer and then substantially planarized to expose the first pole pedestal, first pre-coil layer, and backgap portion. A write gap layer is formed over the exposed first pole pedestal and first coil layer, and a second coil layer is formed above the write gap layer. A second coil insulation layer is formed over the second coil layer, and a second pole is formed over the write gap material and second coil insulation layer, and also over the backgap portion with which it is magnetically connected.[0020]
• Further embodiments are directed to forming a second pole pedestal within the recording device, forming a read element connected to the recording device, attaching the recording device and the read element to a load beam, and attaching a pre-amp chip to the load beam, to the recording device, and to the read element. Still other embodiments include incorporating the recording device and read element within a read/write head, combining the read/write head with a suspension system, and providing a support system for supporting the magnetic medium proximate to the read/write head.[0021]
• These and other advantages of the present invention will become apparent to those skilled in the art upon a reading of the following descriptions of the invention and upon studying the several figures of the drawings.[0022]
BRIEF DESCRIPTION OF THE DRAWINGS
• The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, and like reference numerals designate like elements.[0023]
• FIG. 1A is a partial cross-sectional elevation view of a magnetic data storage system;[0024]
• FIG. 1B is a top plan view along[0025]line1B-1B of FIG. 1A;
• FIG. 2 is a cross-sectional view of a read/write head including a single coil layer according to the prior art;[0026]
• FIG. 3 is a cross-sectional view of a read/write head including two coil layers according to the prior art;[0027]
• FIG. 4 is a perspective view of a head gimbal assembly (HGA) according to the prior art;[0028]
• FIG. 5 is a cross sectional view of a read/write head according to an embodiment of the present invention;[0029]
• FIG. 6 is an ABS view of a write element of the read/write head according to an embodiment of the present invention;[0030]
• FIGS.[0031]7-12 are cross-sectional views of a read/write head at various stages of fabrication, according to an embodiment of the present invention;
• FIG. 13 is an ABS view of a write element of the read/write head according to another embodiment of the present invention; and[0032]
• FIG. 14 is a perspective view of a head gimbal assembly (HGA) according to an embodiment of the present invention.[0033]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
• FIGS. 1A, 1B, and[0034]2-4 were discussed with reference to the prior art.
• FIG. 5 is a cross sectional view of a read/[0035]write head70 of the present invention. The read/write head70 includes a read element72 and awrite element74. Both the read element72 and writeelement74 have surfaces that form part of an air bearing surface (ABS), in aplane76, which can be aligned to face the surface of a magnetic disk16 (see FIGS. 1A and 1B). The read element72 includes afirst shield30, anintermediate layer78, which functions as a second shield, and aread sensor34 that is located within a dielectric medium35 between thefirst shield30 and thesecond shield78. As with the prior art, theread sensor34 can be a magnetoresistive sensor, such as an AMR or GMR sensor. Further, thefirst shield30 and thesecond shield78 can be formed of a ferromagnetic material, such as a nickel iron (NiFe) alloy.
• The[0036]write element74 includes theintermediate layer78, which operates as a first pole, and asecond pole80 which is also formed of a ferromagnetic material, such as NiFe. Thefirst pole78 and thesecond pole80 are connected by abackgap portion82, located distal to the ABS, which is additionally formed of a ferromagnetic material, for example NiFe. Afirst pole pedestal84 is connected to a first pole tip portion86 of thefirst pole78. Further, thefirst pole pedestal84 is aligned with a secondpole tip portion88. Collectively, thefirst pole78,second pole80,first pole pedestal84, andbackgap portion82 form ayoke90. Additionally, the region of thewrite element74 which includes thefirst pole pedestal84, a first pole tip portion86, and a secondpole tip portion88, is referred to as theyoke tip portion92. Within theyoke tip portion92 there is additionally awrite gap89 situated between thefirst pole pedestal84 and the secondpole tip region88. Thewrite gap89 may be formed of any suitable electrically insulating, non-magnetic material such as Silicon dioxide (SiO₂).
• A[0037]first coil layer94, and asecond coil layer96 are disposed between thefirst pole78 and thesecond pole80. As is well known to those skilled in the art, the first and second coil layers94,96 can include one or more coil turns98,100, respectively that are formed of an electrically conductive material, such as copper. Also, as is well known in the art, thefirst coil layer94 can be electrically connected with thesecond coil layer96.
• Both the[0038]first coil layer94 and thesecond coil layer96 are electrically insulated from theyoke90. Thefirst coil layer94 is electrically insulated from thefirst pole78 by a firstpole insulation layer102. The firstpole insulation layer102 extends from thefirst pole pedestal84 to thebackgap portion82, and can be formed of any suitable electrically insulating, non-magnetic material such as silicon dioxide (SiO₂) or alumina (Al₂O₃). The firstpole insulation layer102 can be relatively thin, for example in the range of about 0.1 micron to about 0.5 micron. While the first coil turns98 can be electrically connected in a spiral fashion as is know the art, they are transversely electrically insulated from adjacent other first coil turns98 by a firstcoil insulation layer104. The firstcoil insulation layer104 can include discrete segments disposed between adjacent first coil turns98 as well as between thefirst coil layer94 and thebackgap portion82, and between thefirst coil layer94 and thefirst pole pedestal84. The firstcoil insulation layer104 can be formed of any suitable non-magnetic, electrically insulating material, for example alumina (Al₂O₃). As shown in FIG. 5, the firstpole insulation layer102 also insulates thefirst coil layer94 from thebackgap portion82 and thefirst pole pedestal84. However, in other embodiments the only insulation between thefirst coil layer94 and thefirst pole pedestal84 may be the firstcoil insulation layer104, or alternatively the only insulation may be the firstpole insulation layer102. Similarly, in other embodiments the only insulation between thefirst coil layer94 and thebackgap portion82 may be the firstcoil insulation layer104, or alternatively the only insulation may be the firstpole insulation layer102.
• A[0039]write gap layer106 is disposed above thefirst pole pedestal84, thefirst coil layer94 and the firstcoil insulation layer104. Thewrite gap layer106 can be formed of any suitable non-magnetic, electrically insulating material, such as alumina or silicon dioxide. Thus, thewrite gap layer106 may also be coextensive with thewrite gap89 and electrically insulate thefirst coil layer94 form thesecond coil layer96. A second coil insulation layer108 covers thesecond coil layer96, including between adjacent second coil turns100. In this way, the second coil insulation layer108 provides electrical insulation between adjacent second coil turns100, and between thesecond coil layer96 and thesecond pole80. The second coil insulation layer108 can be formed of any suitable non-magnetic, electrically insulating material, such as alumina, or cured photo resistive material, sometime referred to as “photoresist.”
• FIG. 6 is an ABS view of a[0040]write element74 of the read/write head70, according to an embodiment of the present invention. As can be seen from FIG. 6, a width WP1P of an edge thefirst pole pedestal84 at the ABS is narrower than the first pole tip portion86 of thefirst pole78, and also narrower than the secondpole tip portion88 of thesecond pole80. Since a trackwidth of thewrite element74 is effectively equal to the smallest width of the two components adjoining the write gap, the width WP1P of the edge of thefirst pole pedestal84 essentially defines the trackwidth for thewrite element74. Preferably, the width of the edge of thefirst pole pedestal84 is in the range of about 0.2 micron to about 1.0 micron. [NOTE TO INVENTORS: Please provide a range of trackwidths. (same as in Claim A5)]
• FIGS.[0041]7 -12 are cross-sectional views depicting the formation of thewrite element74 at different stages of fabrication, according to another embodiment of the present invention. As shown in FIG. 7, afirst pole78 surrounded by a build uplayer79 is provided. The first pole can be formed of any suitable ferromagnetic material, such as NiFe. In addition, the build uplayer79 can be formed of any suitable non magnetic, electrically insulating material, such as alumina. Thefirst pole78 andbuildup layer79 can be planerized to form a substantially planer upper surface114. For example, the planerization can be performed using known techniques such as chemical mechanical polishing (CMP), or any other technique that result in a surface114 that is substantially planer.
• As shown in FIG. 8, a[0042]first pole pedestal84 and abackgap portion82 are formed above and electrically connected to thefirst pole78. Thefirst pole pedestal84 andbackgap portion82 can be formed by any suitable method, including various methods and techniques known to those skilled in the art. For example, a first patterned plating mask can be formed above thefirst pole78. Such a mask can be formed, for example, by patterning photoresist as is well known in the art. A ferromagnetic material can then be plated over thefirst pole78 with the first patterned plating mask in place. The ferromagnetic material can be any material having desirable magnetic properties, for example NiFe. The patterned plating mask is then removed, leaving thefirst pole pedestal84 andback gap portion82 above thefirst pole78. Also shown in FIG. 8, a first pole insulation material116 is deposited over thefirst pole pedestal84 andbackgap portion82, as well as thefirst pole78. The first pole insulation material can be any suitable non-magnetic, electrically insulating material, such as silicon dioxide, and can be deposited using techniques well known in the art.
• FIG. 9 depicts the formation of a first pre-coil layer[0043]118 above the first pole insulation material116. The first pre-coil layer118 can include one or more first pre-coil turns120. The pre-coil turns120 can be spirally connected, as is well known in the art, i.e., each pre-coil turn120 can be electrically connected in series with an adjacent pre-coil turn120. As is also well known in the art, the first pre-coil turns120 can wind around thebackgap portion82, with an inside portion Tin of the pre-coil turns120 disposed between thefirst pole pedestal84 and thebackgap portion82, and an outside portion Tout of the first pre-coil turns120 disposed on a side of thebackgap portion82 opposite from thefirst pole pedestal84. Thus, a single turn120aappears in cross section in FIG. 9 on opposite sides of thebackgap portion82, as does another turn120bthat is positioned within the first turn120a.
• The first pre-coil layer can be formed of any suitable electrically conductive material, such as copper. The first pre-coil layer can be formed using known methods, for example by platting. More specifically, a second patterned mask can be formed above the first pole insulation material[0044]116. A first electrically conductive material can then be plated over the first pole insulation material116 with the second patterned plating mask in place. When the second patterned plating mask is removed, the first pre-coil layer remains above the first pole insulation layer116. Over the first pole insulation layer116 and the first pre-coil layer118 is deposited a first coilinsulation layer material122. The first coil insulation material can be formed of any suitable non-magnetic electrically insulating material, such as alumina or silicon dioxide.
• The first coil[0045]insulation layer material122 and the first pole insulation material116 are then substantially planerized to expose thefirst pole pedestal84, thebackgap portion82, and the first pre-coil layer118, as is shown in FIG. 10. This planerization can be performed by any known method, for example chemical mechanical polishing. Such planerization may be continued beyond simply exposing thefirst pole pedestal84, thebackgap portion82, and the first pre-coil layer118, and may also include planerization of thefirst pole pedestal84,backgap portion82, and first pre-coil layer118 themselves. After the planerization, the remaining portion of the first pre-coil layer118 forms afirst coil layer94 having one or more first coil turns98. [e.g., two first coil turns98 are shown in FIG. 10] This planerization process substantially defines the dimension of thefirst pole pedestal84,backgap portion82, and first coil layer124 in the direction perpendicular to surface114.
• As depicted in FIG. 11, a[0046]write gap layer106 is formed over the exposedfirst pole pedestal84 and thefirst coil layer94. Importantly, thebackgap portion82 remains exposed. The writegap material layer106 can be formed of any suitable non-magnetic, electrically insulating material, such as alumina. Asecond coil layer96 is then formed above thewrite gap layer106. The second coil layer is formed of any suitable electrically conductive material, such as copper, and includes one or more second coil turns100. Thesecond coil layer96 can be formed using a variety of known methods and/or techniques. For example, a third patterned plating mask can be formed above thewrite gap layer106. A second electrically conductive material can then be plated above thewrite gap layer106 with the third patterned plating mask in place. The second electrically conductive material can be the same or a different material than the first electrically conductive material, for example copper can be used. The third patterned plating mask can then be removed, with the remaining second conductive material forming thesecond coil layer96.
• A second coil insulation layer[0047]108, shown in FIG. 12 is formed over asecond coil layer96, including filling the spaces between adjacent second coil turns100. The second coil insulation layer108 can be formed of any suitable non magnetic, electrically insulating material, such as cured photoresist.
• A[0048]second pole80 is then formed over thewrite gap layer106,backgap portion82, and second coil insulation layer108. Thesecond pole80 can be formed of any suitable ferromagnetic material, such as NiFe, and can be formed using any of a variety of known methods and techniques, for example, masking and plating. The formation of the read/write head70 can additionally include the formation of other elements, such as an overcoat layer above the second pole. Once the wafer level fabrication is complete, the read/write head70 can be cut from the wafer and lapped to form an ABS in theplane76.
• It should be noted that the completed[0049]write element74 shown in FIG. 12 can include only a total of four coil turns while maintaining a yoke length YL of about 5 microns. Of course, additional coil turns can be included in one or both of thefirst coil layer94, and thesecond coil layer96. For example, a total of about 2 to about 15 coil turns can be included, with even more coil turns being included if desired. To accommodate this range of coil turns, the yoke length YL of thewrite element74 can be in the range of about 3 microns to about 35 microns.
• FIG. 13 shows another embodiment of the present invention in which a[0050]write element130 can further include asecond pole pedestal132 electrically connected to the secondpole tip portion88 of thesecond pole80. Thesecond pole pedestal132 can be formed of any suitable ferromagnetic material, such as NiFe. In such a configuration, thewrite gap89 is defined between thefirst pole pedestal84, and thesecond pole pedestal132. To form thewrite element130, asecond pole pedestal132 can be formed above thewrite gap layer106 before formation of thesecond pole80. The width WP2P of thesecond pole pedestal132 can be defined during plating of ferromagnetic material with a patterned plating mask. Alternatively, before formation of thesecond pole80, the width WP2P can be defined by etching or by ion milling. In addition, at the time thesecond pole pedestal132 is being defined by ion milling, the width WP1P of thefirst pole pedestal84 can also be narrowed by ion milling. In such a case, thefirst pole pedestal84 can be plated wider than the desired final width WP1P. Thus, the width WP2P of thesecond pole pedestal132, can be defined as substantially equal to the width WP1P of thefirst pole pedestal84.
• In yet another embodiment, a[0051]second pole80 of thewrite element74 shown in FIG. 5, can be formed with a secondpole tip portion88 that is narrower than thefirst pole pedestal84 and the first pole tip portion86 at the ABS. With such a configuration, the track width of thewrite element74 is instead a function of the secondpole tip portion88 width at the ABS rather than the width WP1P of the edge of the first pole pedestal.
• FIG. 14 shows a head gimbal assembly (HGA) which includes a base[0052]21 attached to aload beam23. Theload beam23 includes anarm20 attached between the base21 and asuspension22. Thesuspension22 is attached to thearm20 at a first end and is attached to a read/write head70 at an opposite end. Apre-amp chip142 is also located on theload beam23, for example on thearm20 as shown in FIG. 14. Thepre-amp chip142 is electrically connected to the read/write head70 via ametallic interconnection144. Themetallic interconnection144 carries electrical signals between thepre-amp chip142 and the read/write head70. In addition, thepre-amp chip142 is connected to acontroller connector146 that can electrically connect the pre-amp chip to a controller (not shown). Thus, the pre amp-chip142 is also configured to pass electric signals to and from the controller.
• By locating the[0053]pre-amp chip142 closer to the read/write head70, themetallic interconnection144 can have a length L2 that is shorter than the head connector length of the prior art (See FIG. 4), and preferably in the range of 10 mm to 20 mm. With this shorter length L2 the impedance of themetallic interconnection144 is reduced over the prior art. An advantage of the lower impedance inmetallic interconnection144 is it further leads to a decrease in the current rise time of the recording current that is passed through the coil layers94 and96. This reduction in current rise time further reduces the flux rise time at thewrite gap89. Thus, decreasing L2 may lead to higher data recording rates.
• To avoid an impedance mismatch between the[0054]metallic interconnection144 and the read/write head70, and particularly with thewrite element74, the configuration of the present invention can be used. For example thewrite element70 of the present invention can be formed with a total of four coil turns which can cause thewrite element74 to exhibit an impedance of about 3 nanohenrys (nh), substantially similar to the impedance of a head connector having a length L2. Further, because the total number of turns can be included in twodifferent coil layers94 and96, the yoke length YL of thewrite element74 can be shorter than if the total number of coil turns were included in a single coil layer. For example, with a total of four coil turns, the yoke length YL can be about 5 microns. This shorter yoke length YL further facilitates a shorter flux rise time than would be exhibited by a single coil layer of 4 turns. This further reduced flux rise time allows even higher data transfer rates to be achieved. For example, maximum data rates can be achieved of over about 2 gigabytes per second (Gb/s). In addition, with thefirst coil layer94 disposed below thewrite gap layer106, the stack height SH of the write element74 (see FIG. 12) is maintained substantially the same as a write element including only a single coil layer. Thus, difficulties in the formation of thesecond pole80 can be substantially avoided, while providing a greater number of turns, and therefore providing a higher magnetic motive force given the same write current. As an additional advantage, each of the above advantages can be realized with the use of existing fabrication methods, processes, and techniques, while maintaining a desirable time and cost of fabrication with a satisfactory fabrication yield.
• In summary, the present invention provides structures and methods for providing a magnetic recording device with a chip on load-beam arrangement in which the impedance of the head connector is substantially similar to the impedance of the write element. This design allows for the pre-amp chip to be located closer to the recording device for higher data transfer rates. The invention has been described herein in terms of several preferred embodiments. Other embodiments of the invention, including alternatives, modifications, permutations and equivalents of the embodiments described herein, will be apparent to those skilled in the art from consideration of the specification, study of the drawings, and practice of the invention. The embodiments and preferred features described above should be considered exemplary, with the invention being defined by the appended claims, which therefore include all such alternatives, modifications, permutations and equivalents as fall within the true spirit and scope of the present invention.[0055]

Claims (23)

What is claimed is:

1. A recording device for recording data on a magnetic medium, comprising:

a first pole formed of ferromagnetic material and having a first pole tip portion;

a second pole formed of ferromagnetic material and having a second pole tip portion aligned with said first pole tip portion;

a backgap portion formed of ferromagnetic material and magnetically connecting said first pole to said second pole distal said first pole tip portion and said second pole tip portion;

a first pole pedestal formed of ferromagnetic material, magnetically connected to said first pole tip portion, and aligned with said second pole tip portion, wherein said first pole, said second pole, said backgap portion, and said first pole pedestal form a yoke having a characteristic yoke length;

a first pole insulation layer formed of non-magnetic, electrically insulating material, and disposed above said first pole;

a first coil layer formed of electrically conductive material and disposed above said first pole insulation layer and between said first pole pedestal and said backgap portion, wherein said first coil layer is electrically insulated from said first pole, said first coil layer having at least one first coil turn;

a first coil insulation layer formed of electrically insulating material and disposed between said first coil layer and said first pole pedestal, between said first coil layer and said backgap portion, and between transversely adjacent ones of said first coil turns;

a second coil layer formed of electrically conductive material and disposed above said first coil layer, wherein said second coil layer includes at least one second coil turn;

a write gap layer formed of non-magnetic, electrically insulating material and disposed between said first pole pedestal and said second pole tip portion and between said first coil layer and said second coil layer; and

a second coil insulation layer formed of non-magnetic, electrically insulating material, disposed above said write gap layer, and covering said second coil layer, including being disposed between transversely adjacent ones of said second coil turns, wherein said second pole is disposed over said second coil insulation layer.

2. The recording device recited in

claim 1

, wherein said yoke length is in the range of about 3 microns to about 35 microns and wherein a sum of said first coil layer turns and said second coil layer turns is in the range of about 4 to about 15.

3. The recording device recited in

claim 2

, wherein said first coil layer includes no more than two first coil layer turns, said second coil layer includes no more than two second coil layer turns, and said yoke length is in the range of about 3 microns to about 7 microns.

4. The recording device recited in

claim 1

, wherein said first pole pedestal includes an edge that forms an air bearing surface, and wherein a trackwidth of said recording device is a function of a width of said edge.

5. The recording device recited in

claim 4

, wherein said width of said edge is in the range of about 0.2 micron to about 1.0 micron.

6. The recording device recited in

claim 1

, further comprising:

a second pole pedestal formed of ferromagnetic material, disposed between said write gap layer and said second pole, and magnetically connected to said second pole, wherein said yoke includes said second pole pedestal.

7. A data transfer device for exchanging data with a magnetic medium, comprising:

a recording device including;

a first pole formed of ferromagnetic material and having a first pole tip portion,

a second pole formed of ferromagnetic material and having a second pole tip portion aligned with said first pole tip portion,

a backgap portion formed of ferromagnetic material and magnetically connecting said first pole to said second pole distal said first pole tip portion and said second pole tip portion,

a first pole pedestal formed of ferromagnetic material, magnetically connected to said first pole tip portion, and aligned with said second pole tip portion, wherein said first pole, said second pole, said backgap portion, and said first pole pedestal form a yoke having a characteristic yoke length,

a first pole insulation layer formed of non-magnetic, electrically insulating material, and disposed above said first pole,

a first coil layer formed of electrically conductive material and disposed above said first pole insulation layer and between said first pole pedestal and said backgap portion, wherein said first coil layer is electrically insulated from said first pole, said first coil layer having at least one first coil turn,

a first coil insulation layer formed of electrically insulating material and disposed between said first coil layer and said first pole pedestal, between said first coil layer and said backgap portion, and between transversely adjacent ones of said first coil turns,

a second coil layer formed of electrically conductive material and disposed above said first coil layer, wherein said second coil layer includes at least one second coil turn,

a write gap layer formed of non-magnetic, electrically insulating material and disposed between said first pole pedestal and said second pole tip portion and between said first coil layer and said second coil layer, and

a second coil insulation layer formed of non-magnetic, electrically insulating material, disposed above said write gap layer, and covering said second coil layer, including being disposed between transversely adjacent ones of said second coil turns, wherein said second pole is disposed over said second coil insulation layer; and

a load beam to which said recording device is affixed; and

a pre-amp chip disposed on said load beam, electrically connected to said recording device, and configured to be electrically connected to a controller, wherein said pre-amp chip is configured to pass electrical signals to and from said controller and said recording device.

8. The data transfer device recited in

claim 7

, wherein a distance between said recording device and said pre-amp chip is in the range of about 5 mm to about 25 mm.

9. The data transfer device recited in

claim 7

, further comprising:

a read element for accessing data on said magnetic medium, said read element being connected to said recording device and being electrically connected to said pre-amp chip.

10. The data transfer device recited in

claim 9

, wherein said read element includes:

a first shield;

a read sensor disposed between said first shield and said first pole, wherein said first pole is configured to provide a second shield for said read sensor.

11. The data transfer device recited in

claim 7

, wherein said yoke length is in the range of about 3 microns to about 35 microns and wherein a sum of said first coil layer turns and said second coil layer turns is in the range of about 4 to about 15.

12. The data transfer device recited in

claim 11

, wherein said first coil layer includes no more than two first coil layer turns, said second coil layer includes no more than two second coil layer turns, and said yoke length is in the range of about 3 microns to about 7 microns.

13. The data transfer device recited in

claim 7

, wherein said pre-amp chip is located sufficiently distant from said recording device such that an impedance of a connector between said recording device and said pre-amp chip is substantially equal to an impedance of said recording device.

14. The data transfer device recited in

claim 9

, further comprising:

a medium support that is capable of supporting said magnetic medium and moving said magnetic medium in relation to a read/write head that includes said recording device and said read element; and

a read/write head support system for suspending said read/write head above said medium, said support system including said load beam and said pre-amp chip.

15. The system as recited in

claim 14

, wherein said read/write head support system includes means for moving said read/write head relative to said medium.

16. The system as recited in

claim 14

, wherein said medium support includes:

a spindle on which said medium can be supported, having an axis about which said medium can rotate; and

a medium motor connected to said spindle and capable of facilitating said moving of said medium relative to said read/write head.

17. A method for forming a data transfer device for exchanging data with a magnetic medium, said method comprising:

forming a recording device, including:

providing a first pole formed of ferromagnetic material;

substantially planarizing said first pole;

forming a first pole pedestal above and magnetically connected to said first pole;

forming a backgap portion above and magnetically connected to said first pole;

depositing a first pole insulation material over said first pole pedestal, said first pole, and said backgap portion;

forming a first pre-coil layer formed of a first electrically conductive material, above said first pole insulation layer, wherein said first pre-coil layer has at least one first pre-coil turn;

depositing a first coil insulation layer material over said first pre-coil layer;

substantially planarizing said first coil insulation layer material and said first pole insulation material to expose said first pole pedestal, said first pre-coil layer, and said backgap portion, wherein said first pre-coil layer forms a first coil layer having at least one first coil turn, and wherein said first coil insulation material forms a first coil insulation layer that electrically insulates said at least one first coil turns from each other;

forming a write gap layer over said exposed first pole pedestal and said first coil layer;

forming a second coil layer above said write gap layer, wherein said second coil layer includes at least one second coil turn;

forming a second coil insulation layer over said second coil layer, wherein said second coil insulation layer electrically insulates said at least one second coil turns from each other; and

forming a second pole of ferromagnetic material over said write gap material said second coil insulation layer, and said backgap portion, wherein said second pole is magnetically connected to said backgap portion.

18. The method as recited in

claim 17

, wherein forming a first pole pedestal and forming a backgap portion includes:

forming a first patterned plating mask above said first pole;

plating ferromagnetic material over said first pole with said first patterned plating mask; and

removing said first patterned plating mask;

wherein forming a first pre-coil layer includes:

forming a second patterned plating mask above said first pole insulation material;

plating a first electrically conductive material over said first pole insulation material with said second patterned plating mask; and

removing said second patterned plating mask; and

wherein forming said second coil layer includes:

forming a third patterned plating mask above said write gap layer;

plating a second electrically conductive material above said write gap layer with said third patterned plating mask; and

removing said third patterned plating mask.

19. The method as recited in

claim 17

, further comprising:

forming a read element connected to said recording device, including:

providing a first shield;

forming a read sensor between said first shield and said first pole, wherein said first pole is configured to operate with said read sensor as a second shield; and

magnetically insulating said read sensor from said first shield and said first pole.

20. The method as recited in

claim 17

, further comprising:

forming a second pole pedestal of ferromagnetic material, disposed between said write gap layer and said second pole, and magnetically connected to said second pole, wherein said yoke includes said second pole pedestal;

wherein forming said second pole pedestal includes,

forming a fourth patterned plating mask above said write gap layer;

plating ferromagnetic material over said write gap layer with said fourth patterned plating mask; and

removing said fourth patterned plating mask.

21. The method as recited in

claim 19

, further comprising:

attaching said read element connected to said recording device to a load beam;

attaching a pre-amp chip to said load beam;

electrically connecting said pre-amp chip to said read element; and

electrically connecting said pre-amp chip to said recording device.

22. The method as recited in

claim 21

, wherein attaching said pre-amp chip to said load beam further includes locating said pre-amp chip sufficiently distant from said recording device such that an impedance of a connector between said recording device and said pre-amp chip is substantially equal to an impedance of said recording device.

23. The method as recited in

claim 21

, further comprising:

incorporating said recording device and said read element within a read/write head;

incorporating said read/write head with a suspension system for suspending said read/write head over a magnetic medium, said suspension system further including said load beam and said pre-amp chip; and

providing a support system for supporting said magnetic medium in proximity to said read/write head.

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