Thin film write head having a laminated, flat top pole with bottom shaper and method of fabrication

A head for use in data recording, comprising:

• first and second magnetic poles each including an open end and an opposite closed end, the poles being joined together at the closed ends and opposing each other at the open ends, an interior space being defined between the poles and between the open ends and the closed ends, and wherein the second magnetic pole includes a top pole layer of magnetic material distal to the first pole and a lamination layer of electrical insulation material proximal to the first pole;
• a write gap pedestal disposed adjacent the open end of the first pole and the second pole and between the poles;
• a write gap comprising non-magnetic, electrically insulating material between the write gap pedestal and the lamination layer of the second pole;
• an electrically conducting coil having a portion thereof passing through the interior space;
• and
• an insulator disposed within the interior space and electrically isolating the coil from the second pole.

A system for storing and retrieving digital data to and from a magnetic recording media, comprising:

• a head assembly positionable adjacent the magnetic recording media comprising:
• a read head;
• and
• a write head comprising:
• a first magnetic pole having a front portion and an opposite back portion;
• a write gap pedestal disposed above the front portion of the first pole and having an upper pedestal layer comprising a high magnetic moment material and including an upper surface substantially defining a plane;
• a write gap layer deposited on the upper surface of the upper pedestal layer;
• a second magnetic pole disposed above the first magnetic pole and including a top pole layer with a substantially planar upper surface and a bottom shaper disposed between the top pole layer and the first magnetic pole, wherein the bottom shaper comprises a high magnetic moment material and includes an upper surface that is substantially coplanar with the plane defined by the upper surface of the upper pedestal layer;
• and
• an electrically conducting coil disposed between the first and the second magnetic pole;
• and
• a drive device for coupling to the media so as to move the media with respect to the head assembly.

A method of fabricating a thin film write head, comprising:

• providing a first magnetic pole upon which an electrically conducting coil with insulation materials and a pedestal has been deposited, wherein the insulation materials and pedestal have been planarized to provide a substantially continuous, coplanar upper surface;
• depositing a film of high magnetic moment material on the upper surface of the coil insulation materials and pedestal;
• positioning photoresist over the deposited film in a pattern configured to define by shielding a bottom shaper and an upper pedestal layer in the film and by leaving a gap portion between the bottom shaper and upper pedestal layer unshielded;
• removing the film material in the gap portion;
• filling the gap portion with electrical and magnetic insulation material to form an insulation insert between the bottom shaper and the upper pedestal layer, wherein the insulation insert, the bottom shaper, and the upper pedestal layer have substantially coplanar upper surfaces;
• depositing a layer of write gap material on the upper surface of the upper pedestal layer and at least a portion of the insulation insert;
• and
• forming a second magnetic pole over the bottom shaper, the insulation insert, and layer of write gap material.