Lead overlay sensor with improved current path

A magnetic disk drive comprising:

• at least one magnetic head assembly that includes a write head and a read head;
• the read bead including;
• nonmagnetic electrically nonconductive first and second read gap layers;
• a sensor located between the first and second read gap layers;
• ferromagnetic first and second shield layers;
• and
• the first and second read gap layers being located between the first and second shield layers;
• the sensor including;
• a pinned layer structure;
• a ferromagnetic free layer having a magnetic moment that is free to rotate in response to a field signal;
• a nonmagnetic electrically conductive spacer layer located between the free layer and the pinned layer structure;
• and
• the read sensor being partially bounded by its top, bottom, first side and second side surfaces wherein the surfaces are substantially perpendicular to said head surface and the first and second side surfaces join the top and bottom surfaces;
• first and second hard bias layers wherein each first and second hard bias layer is partially bounded by its top, bottom and an end surfaces wherein the surfaces are substantially perpendicular to said head surface and the end surface joins the top and bottom surfaces;
• the end surfaces of the first and second hard bias layers being adjacent the first and second side surfaces of the sensor respectively for longitudinally magnetically biasing the sensor;
• the top surface of the sensor having a top middle surface portion and first and second top end surface portions with the too middle surface portion being located between the first and second top end surface portions;
• first and second leads overlaying the top surfaces of the first and second hard bias layers respectively and overlaying the first and second top surface end portions respectively of the sensor;
• first and second insulation layers with the first insulation layer being located between the ton surface of the first hard bias layer and the first lead layer and the second electrical insulation layer being located between the top surface of the second hard bias layer and the second lead layer;
• each of the first and second insulation layers made of a material which has a greater electrical resistivity than a material of the first and second hard bias layers;
• third and fourth insulation layers with the third insulation layer being located between the end surface of the first hard bias layer and the first side surface of the sensor and the fourth insulation layer being located between the end surface of the second hard bias layer and the second side surface of the sensor
• the third and fourth insulation layers constructed of a material which has a greater electrical resistivity than the material of the first and second hard bias layers;
• and
• a housing;
• the magnetic medium being supported in the housing;
• a support mounted in the housing for supporting the magnetic head assembly with said head surface facing the magnetic medium so that the magnetic head assembly is in a transducing relationship with the magnetic medium;
• a motor for moving the magnetic medium;
• and
• a processor connected to the magnetic head assembly and to the motor for exchanging signals with the magnetic head assembly and for controlling movement of the magnetic medium.

A method of making a magnetic head assembly, which has a head surface, comprising the steps of:

• forming a read sensor partially bounded by top, bottom, first side and second side surfaces wherein the surface are substantially perpendicular to said head surface and the first and second side surfaces join the top and bottom surfaces;
• forming first and second hard bias layers wherein each first and second hard bias layer is partially bounded by top, bottom and an end surfaces wherein the surfaces are substantially perpendicular to said head surface and the end surface joins the top and bottom surfaces;
• forming the end surfaces of the first and second hard bias layers adjacent the first and second side surfaces of the sensor respectively for longitudinally magnetically biasing the sensor;
• forming the top surface of the sensor with a top middle surface portion and first and second top end surface portions with the top middle surface portion being located between the first and second top end surface portions;
• forming first and second leads overlaying the top surfaces of the first and second hard bias layers respectively and further overlaying and being electrically connected to the first and second top surface end portions respectively of the sensor;
• forming first and second insulation layers with the first insulation layer located between the top surface of the first hard bias layer and the first lead layer and the second insulation layer located between the top surface of the second hard bias layer and the second lead layer;
• forming each of the first and second insulation layers of a material which has a greater electrical resistivity than a material of the first and second hard bias layers;
• forming the third insulation layer between the end surface of the first hard bias layer and the first side surface of the sensor and the fourth insulation layer between the end surface of the second hard bias layer and the second side surface of the sensor;
• and
• forming third and fourth insulation layers of a material which has a greater electrical resistivity than the material of the first and second hard bias layers.