Thin-film magnetic transducer with a multitude of magnetic flux interactions

A method for making a thin film magnetic transducer from a film having a plurality of layers, comprising the steps of:

• forming a yoke having a plurality of magnetic flux circuits disposed about the center of the transducer such that there exists for each magnetic flux circuit two terminal end portions for coupling magnetic flux into and out of each magnetic flux circuit, each magnetic flux circuit being formed with a first pole piece in one layer of the film and a second pole piece in another layer of the film, forming the yoke comprising the steps of:
• connecting the first and second pole pieces of each magnetic flux circuit together through a corresponding distal via traversing the layers of the film and disposed on a portion of the magnetic flux circuit distal to the terminal end portions relative to the center of the transducer;
• connecting the terminal end portion of each magnetic flux circuit to a corresponding terminal end of an adjacent magnetic flux circuit through a corresponding proximal via traversing the layers of the film and disposed proximal to the center of the transducer;
• and
• forming said pole pieces such that the easy axis of magnetization of each pole piece is oriented substantially perpendicular to a flux conduction path therein lying along a line of sight between the centers of the corresponding distal and proximal vias at opposite ends thereof, and such that the line of sight in the first pole piece and the line of sight in the second pole piece intersect at the distal via connecting the first and second pole pieces, said magnetic flux circuits being formed such that there are at least two pole pieces in each of said layers having non-parallel easy axes;
• forming a first tip pole piece having a pole tip in said one layer of the film such that one end of said first tip pole piece is adapted for positioning adjacent to a magnetic medium for coupling magnetic flux between the medium and the yoke, and such that the other end of the first tip pole piece is connected to a corresponding terminal end portion of an adjacent magnetic flux circuit through a corresponding proximal via;
• forming a second tip pole piece having a pole tip in said other layer of the film such that one end of said second tip pole piece is adapted for positioning adjacent to the magnetic medium for coupling magnetic flux between the medium and the yoke, and such that the other end of the second pole piece is connected to a corresponding terminal end portion of an adjacent magnetic flux circuit through a corresponding proximal via;
• and
• forming a coil to have a plurality of turn intertwined with the yoke and passing between the distal and proximal vias, so that the distal vias are exterior to the coil and the proximal vias are interior to the coil, to provide at least four magnetic flux interactions between the coil and the yoke.

A method for manufacturing a thin film magnetic transducer from a film having a plurality of layers, comprising the steps of

• first depositing at least one magnetic pole piece onto the first layer of a substrate in the presence of a magnetic field to induce an easy axis in the deposited pole pieces having a first orientation substantially perpendicular to a flux conduction path lying along a line of sight extending between the respective centers of two spaced-apart areas where vias are to be subsequently formed on each firstly deposited pole piece,
• reorienting the substrate relative to the magnetic field and secondly depositing at least one magnetic pole piece onto the first layer of the substrate in the presence of the magnetic field to induce an easy axis in the second deposited pole pieces having a second orientation different from said first orientation and substantially perpendicular to a flux conduction path lying along a line of sight extending between the respective centers of two spaced-apart areas where vias are to be subsequently formed on each secondly deposited pole piece,
• forming at least one electrical coil layer onto the first layer of the substrate, and at least one insulating layer onto the electrical coil layer of the substrate, said insulating layer being formed with an opening above each area on the firstly and secondly deposited pole pieces where one of said vias is to be formed,
• reorienting the substrate relative to the magnetic field and thirdly depositing at least one magnetic pole piece onto the insulating layer of the substrate, each thirdly deposited pole piece covering two of said insulating layer openings such that corresponding ones of said vias are thereby formed, and each thirdly deposited pole piece being deposited in the presence of the magnetic field to induce an easy axis therein having a third orientation substantially perpendicular to a flux conduction path lying along a line of sight extending between the respective centers of the vias formed thereby, and
• reorienting the substrate relative to the magnetic field and fourthly depositing at least one magnetic pole piece onto the insulating layer of the substrate, each fourthly deposited pole piece covering two of said insulating layer openings such that corresponding ones of said vias are thereby formed, and each fourthly deposited pole piece being deposited in the presence of the magnetic field to induce an easy axis therein having a fourth orientation different from said third orientation and substantially perpendicular to a flux conduction path lying along a line of sight extending between the respective centers of the vias formed thereby.