CN1064161C - Integrated transducer-suspension structure for longitudinal recording - Google Patents

Abstract

The invention provides a combined thin-film magnetic head sensor and suspension system for longitudinal recording, the first and second pole pieces are wider in the back gap area and narrower in the pole head; the suspension layer of the elastic material film layer covers at least A second pole piece horizontal portion electrically and magnetically insulated from the second pole piece and the coil, the elastic material extending beyond the back gap region; a second pole piece vertical portion having a substantially vertical portion on one end adjacent to the magnetic gap layer and at an offset from The location on the second end of the substantially vertical portion at an angle. A method of making the system and a disk drive assembly using the system are also provided. The invention expands the application range of the magnetic head and can be produced in batches.

Description

Combined thin-film magnetic head and suspension system for longitudinal recording and manufacturing method thereof

US Patent 4,624,048, Hinkel et al., issued November 25, 1986, assigned to the assignee of the present invention, discloses a method of manufacturing a head substrate for use in the present invention.

US Patent No. 3,849,800 to Cuzner et al., issued November 19, 1974, assigned to the assignee of the present invention, discloses a rotary actuator in a drive mechanism used in the present invention.

US Patent 4,251,841 to Jacobs, issued February 17, 1981, assigned to the assignee of the present invention, discloses a disc-shaped substrate material useful in the present invention.

The present invention relates to a removable magnetic memory and its recording element, in particular to a sensor-suspension device suitable for mass production and its manufacturing method,

Removable magnetic storage, especially disk drives, is quickly becoming the storage of choice. Because it has expandable persistent memory storage capacity and relatively low cost. Accurately retrieving the stored information from these memories is key, requiring the sensor to be located as close to the medium as possible, preferably with the transducer in contact with the medium.

Disk files are information storage devices that use at least one rotatable disk with concentric data tracks that contain data information. The sensor-slider-suspension combination consists of a sensor for reading data from or writing data to each of the magnetic tracks; a flying magnetic track; and a levitation device for elastically holding the slider and the sensor on the magnetic track. A positioner is attached to the combination to move the sensor to the desired track and keep the sensor on the track centerline while reading or writing. The sensor is mounted on an air bearing slider that uses the air cushion created by the rotating disk to support the sensor close to the magnetic track. However, it is possible to bring the sensor into contact with the disk. The suspension has high spring stiffness and dimensional stability between the slider and the lever. The suspension is required to hold the sensor and slider against the data surface of the disk with the lowest possible load force. The actuator is controlled to position the sensor on the correct track according to the desired data for the read operation, or to position the sensor on the correct track for the data arrangement during the write operation.

In a conventional disk drive, the sensor and its slider are constructed separately from the suspension and then connected by precise operation controlled by the operator. The components are small and must be positioned precisely relative to each other. The sensor must be positioned precisely on the magnetic track, and accordingly the levitation must be positioned precisely on the slider. The suspension must be elastic, articulated, and allow the slider to roll in the direction of disk rotation, but also prevent wobbling. Any error in the placement of the suspension on the slider impairs its performance and life. Even if the levitation is properly positioned with the slider, it is necessary to have the wires connecting the sensor connected to the sensor. The wires usually run directly along the suspension to an amplifier located on the suspension or on the actuator. Wires certainly do not enhance the elastic stiffness of the slider while providing good electrical interconnection.

Typically, wires are connected by the operator by soldering, for example, to both the output of the sensor and the amplifier. Errors can again cause damage to the entire combination.

The unique problem caused by the contact or light touch of the sensor/slider combination or the head with the media is that it causes the media to wear and possibly break it. In order to reduce wear and the possibility of "crushing", it is known that the volume of the suspension system must be minimized. The small size allows for better control of "bumping" the head on the media, thereby reducing the potential for damage and wear to the media.

To this end, a number of mechanisms have been disclosed which use a "reed" approach to make the sensor-levitation. In a configuration that works in perpendicular recording applications, the reed arrangement allows easy formation of the head and suspension: (i) precise throat height control; (ii) precise placement of contact recording transducers or by formation of air bearings to obtain prescribed flying height; (iii) slider and suspension connection, and (iv) ease of wire routing. These structures, such as those described in Hamilton US Pat. No. 5,041,932, include, for example, a horizontal sensor having a horizontal first pole piece and a horizontal second pole piece. The second pole piece has a vertical portion that is aligned with the first pole piece. Magnetic gaps separated from each other are formed.

As mentioned above, contact recording can obtain higher signal and greater resolution, not limited by the change of levitation height. Unfortunately, wear from contact recording is typically estimated at 400 microinches over the life of the document, which cannot be tolerated. Another major drawback is that previous heads of this type were only suitable for perpendicular recording and not for longitudinal media. All of these make the perpendicular recording head of the above-mentioned design unsuitable for high-density recording.

It is an object of the present invention to provide an enhanced mobile magnetic memory having a magnetic head structure comprising an enhanced suspension-sensor combination.

Another object of the present invention is to provide an enhanced suspension-sensor combination magnetic head structure.

Yet another object of the invention is to make a sensor-suspension suitable for longitudinal recording.

A further object of the present invention is to manufacture a longitudinal magnetic head which is wear-resistant and has a variable shape of the contact bumps.

The present invention is a combined device of suspension device and sensor magnetic head for longitudinal recording, which can be used for contact recording or flying on the medium. The sensor includes a horizontal first pole piece and a second pole piece with a horizontal section and a vertical section in section. A magnetic gap is formed between the first pole piece and the vertical portion of the second pole piece. The shape of the pole piece should avoid magnetic saturation and have a narrow pole head. The levitation means consists essentially of two layers, the first being an insulating layer which separates the first horizontal pole piece from the horizontal portion of the second pole piece. The second layer is an insulating layer which covers and protects the sensor layer.

In the manufacturing method of the combination structure of the sensor-suspension device, contact bumps of many patterned photoresists in a row and column structure are formed on the substrate. A release layer is then deposited on the substrate. A pattern is formed on each contact bump to partially contact the first pole piece. A thick rear air gap layer of magnetic material is deposited on each first pole piece. A thick layer of electrically and magnetically insulating material is deposited after the wear layer. This layer is the main part of the suspended parts in the combined structure. The suspension layer is ground flat and forms a primary coil layer on top of the suspension film for each pole piece. A second pole piece of a magnetic material layer is deposited on the insulating layer corresponding to each first pole piece and at least partially covers the primary coil layer. The second pole piece layer is covered with an insulating layer, but is allowed to be in contact with the primary coil. A coil circuit is then formed on the insulating layer along wires connected to the coil circuit. Wires and subsequently deposited conductive plugs are used to interface with each sensor's drive circuitry (not shown). A second thick layer of electrically and magnetically insulating material is then deposited to form the second and final major portion of the suspended portion of the combined structure, the top of this layer being ground away to make electrical contact with the already formed conductive plug. Since the assemblies are deposited on the circular substrate in rows and columns, each assembly is then divided into rows or rows of assemblies.

The ends of some of the row assemblies are ground and a magnetic gap layer is deposited. Contact channels are then formed in the magnetic gap layer, exposing the second pole piece layer. A third pole piece of magnetic material is patterned on each row to form a vertical portion of the second pole piece. A protective coating is then deposited on the finished rows of suspension and sensor assemblies. The component rows are then split into many individual composite structures. Next, the substrate is removed by dissolving or etching the separation, leaving the partially fabricated composite structure. Removal of the air gap portion, the third pole piece and the final protective layer extending below the original contact completes the combined structure. Preferably, a deposited aluminum oxide (Al ₂ O ₃ ) layer is used to form the suspended device. Cutting the alumina layer then separates the formed suspension from the substrate surface to form the desired suspension structure. Removal of the substrate is preferably accomplished using a release layer.

Since the present invention provides a narrow air gap between magnetic poles on the contact bump surface, longitudinal recording is possible. This has just greatly improved the applicability of the present invention, and its scope of application obviously exceeds prior art. Furthermore, the present invention is essentially a planar deposition structure, so that the main processing processes of its components can be carried out directly on the circular substrate surface. This greatly improves the practicability of the present invention and enables its combination to be mass-produced.

Another advantage of the present invention is that wear-resistant materials are used in the structure of the magnetic head, so that the pole head area of the magnetic head is protected.

The foregoing and other objects, features and advantages of the present invention will be described in detail below in conjunction with preferred embodiments of the present invention and with reference to the accompanying drawings. in,

Figure 1 is a top view of a magnetic recording mechanism utilizing the suspension assembly of the present invention positioned by a rotary actuator in sensing relationship to the disk surface of a disk file;

Figure 2 is a perspective view of a sensor-suspension assembly made in accordance with the present invention for use with the disk drive of Figure 1;

Figure 3 is a perspective view of a substrate on which a number of structures arranged in rows and columns to form the assembly shown in Figure 2 are formed;

Fig. 4 is a sectional view along line 4-4 in Fig. 3;

Figure 5 is a perspective view taken of a row of structures on the substrate shown in Figure 3, mounted for further processing;

6A and 6B are cross-sectional views of embodiments of sensors of the present invention; and

Fig. 7 is a perspective view of the sensor of the present invention without the insulating layer and the conductor layer.

The preferred embodiment of the present invention is preferably used with large multiple disk drives, but can also be used with a single disk drive commonly used in personal microcomputers, or any other form of media drive, such as a tape drive. The data recording disk file shown in FIG. 1 comprises a housing 8 in which is mounted a rotary rail actuator 10 , an associated storage disk 12 and drive means 13 for rotating the disk 12 . The rotary actuator 10 drives the assembly of the present invention to move on a magnetic disk 12 in an arcuate path. The rotary actuator 10 includes a voice coil motor including a coil 14 movable in the magnetic field of a fixed permanent magnet assembly with an iron core 16 . The actuator arm 20 is fixed on the movable coil 14 . The other end of the actuator arm 20 is fixed on the sensor-suspension device assembly 22 of the present invention and manufactured according to the method described above. Assembly 22 includes a sensor-slider 24 and a suspension section 26 . Suspension section 26 may support sensor slider 24 on an air bearing or cushion created by disk 12 rotation on the disk 12 surface. Preferably, the suspension section 26 supports the sensor-slider 24 in contact with the surface of the disk 12 . Air bearing or air bearing surface refers to the surface of the transducer that is parallel to and adjoins the surface of the disk. It includes two configurations, one is designed so that the sensor flies over the disk during operation, and the other is designed so that the sensor is in contact with the recording medium, disk 12, during operation. Actuator arm 20 may comprise a plurality of arms, each arm supporting its respective assembly 22, each assembly 22 corresponding to the surface of each disk located in the data recording disk drive assembly. Thus, for example, the magnetic disk 12 may also have an assembly 22 mounted on the actuator arm 20 such that it corresponds to the surface of the recording medium on the lower surface of the magnetic disk 12 . In addition, other assemblies also correspond to the top and bottom sides of other disks included in the disk drive assembly. Access to the sensors in the disk drive assembly is controlled by actuator 10 .

The suspension segments 26 in the sensor-suspension assembly 22 give the sensor-slider 24 a load that is always perpendicular to the disk 12 surface. This vertical load keeps the sensor-slider 24 on or above the disk 12 . During the rotation of the magnetic disk 12 by the drive means 13, the assembly 22 remains in contact with the magnetic disk 12 for reading or writing data. As an alternative, the assembly 22 can be designed to fly above the disk 12 by utilizing the buoyancy or upward force generated between the sensor-slider 24 and the disk 12 against the load imposed on the sensor-slider 24 by the suspension section 26 . Contact logging is a preferred embodiment of the invention.

In operation, the sensor-slider 24 is moved to a desired one of the concentric data tracks on the data surface of the magnetic disk 12 by means of the coil 14 which moves in the magnetic field of the magnet assembly. The sensor-slider 24 is required to move rapidly from one magnetic track to the other. The sensors of the slider 24 must be actually positioned on the desired magnetic track in the shortest possible time. The rotary actuator used in the present invention is as described in US 3849800. It should be noted that the actuator 10 shown in FIG. 1 is a rotary actuator, and other types of linear actuators used in conventional disk files can also be used in the present invention.

The suspension section 26 of the assembly 22 must be radially rigid and substantially elastic in the pitch and roll directions as it holds the transducer of the slider 24 above the data surface of the disk 12. An integrated circuit package 28 may also be formed on the suspended section 26 of the assembly 22, if desired. Reference numeral 28 designates an integrated circuit amplifier. An enlarged structure of the assembly 22 shown in FIG. 1 is shown in FIG. 2 .

Referring now to FIG. 2, like numerals indicate like features and structural elements in the various figures. Assembly 22 is shown on disk 12 . Disk 12 rotates in the direction indicated by arrow 36 . The sensor 38 of the sensor-slider 24 (vertical pole cross-section shown) is located adjacent to the magnetic disk 12 for reading or writing magnetic transitions on the magnetic disk 12 . The level sensor-suspension of the present invention is positioned parallel to the disk 12 for ease of illustration of the invention since most disk drives have disks mounted horizontally. Obviously, vertically mounted disks are also covered equivalently, in that assembly the "horizontal" and "vertical" units would necessarily be reversed, but the sensor would still run parallel to the surface of the disk.

Suspension section 26 suspends sensor 38 above disk 12 . The suspension segment 26 in this embodiment includes a first insulating layer 40 and a second insulating layer 42 . A conductive circuit layer (not shown) is encapsulated between these two layers. The supporting body constituted by the suspended segments is held by the first and second insulating layers 40 and 42 . Sensor 38 is electrically connected to the conductive circuit layer. Electrical connection conductor bumps 48 are provided to provide interconnection to adjacently located amplifiers. Integrated circuit amplifiers (not shown) may be provided in place of conductive bumps. The deposited integrated circuit amplifier in Figure 1 is one possible example of an amplifier arrangement.

Insulating layers 40 and 42 insulate the conductive layer from the possibly conductive magnetic portion of sensor 38 . The two insulating layers 40 and 42 provide a suspension for positioning the clamp sensor 38 on the magnetic tracks of the magnetic disk 32 .

FIG. 3 illustrates the process steps for forming the assembly 22 of the structure shown in FIG. 2 . Mass fabrication of assembly 22 is accomplished using a non-magnetic circular substrate 50 . The thickness T of the substrate 50 should be sufficient to support the structure under fabrication. A plurality of assemblies 22 are deposited on a substrate 50 in rows and columns. Each row 52, shown as 5 rows, and each column 54, shown as 4 columns, illustrate the structure of modules that make up multiple rows, each row of modules can then be subdivided into individual cells. On a monolithic substrate 50, more or fewer assemblies than those shown in rows 52 and columns 54 shown in FIG. Size.

Still referring to FIG. 3 , a row 52A is cut from substrate 50 with saw 56 . Row 52A has sensor portion 38 at end face 59 . Row 52A is reprocessed by the method shown in FIGS. 5 and 6 and then divided into individual units by saw 58 or other cutting means, as shown in FIG. 3 . FIG. 4 shows a cross-sectional view of the deposited layer deposited on a substrate 50 as a first part of the assembly 22. As shown in FIG.

Referring now to FIG. 4 , assembly 22 includes a number of layers that make up sensor-slider 24 and suspension segment 26 . In cross section, the level sensor considered by the invention constitutes all or at least a part of the sensor-slider 24 shown in FIGS. 1 and 2 . The sensor comprises a first pole piece 62 positioned horizontally, ie parallel to the contact plane of the magnetic disk (not shown). The first pole piece 62 is formed with an inclined contact area 63 which may be formed by embossing the surface of the original substrate 50 as shown in FIG. 4 . The surface of the circular substrate 50 is coated with a release layer 60 prior to depositing the material for making the pole piece 62 . The separation layer 60 is dissolved to separate the circular substrate 50 from the pole piece 62 in a subsequent process. A magnetic element 64 connected to pole piece 62 is deposited. After the magnetic element 64 is formed, the entire surface of the separation layer 60 of the circular substrate 50 is coated with a wear-resistant material 65 and an insulating layer 66 . Abradable layer 65 covers most of the interface between sensor portion 24 and magnetic disk 12 (see FIG. 2 ). Wear resistant layer 65 and insulating layer 66 are ground down after deposition to provide a smooth surface for subsequently deposited layers and to expose the top surface of element 64 . A first set of conductor strips 68 for the sensor coils are then formed on insulating layer 66 and coated with a coil insulating layer 70 of electrically insulating material. The horizontal portion 72 of the second pole piece is then formed on the insulating layer 70 . The second pole piece horizontal portion 72 is in contact with the magnetic element 64 to form the rear air gap of the sensor. An additional layer of coil insulation 74 is deposited over the entire surface of the circular substrate. On the coil insulation layer 74 is deposited a second set of coil conductor strips 76 . A second set of coil conductor strips 76 interconnects the first set of coil conductor strips, providing an excitation conductor coil around the horizontal portion 72 of the second pole piece of the sensor portion 24 . Conductor strips 68 and 76 are electrically connected to conductor layer 78 deposited on conductor coil insulating layer 74 to form the coil. The coil is integrated with the magnetic element of the sensor, enabling the sensor to perform magnetic conversion reading and writing on the magnetic disk 12 . The signal induced by the coil passes through the conductor plug 80 formed at the free end of the conductor layer 78 and enters the circuit system (not shown) from the conductor layer. A second electrically insulating layer 82 is deposited over the conductor coil strip 76 and the conductor layer 78 . The second insulating layer 82 and the first insulating layer 66 are supporting structures of the suspension section 26 . Conductor bumps 48 (see FIG. 2 ) are then formed on second insulating layer 82 and connected to conductor studs 80 . Conductor bumps 48 may be interconnected with corresponding disk drive circuitry via integrated circuit 28 as shown in FIG. 1 .

After the deposition process shown in FIG. 4 is completed, the circular substrate 50 is cut into rows, as shown in FIG. 3 . In FIG. 3, row 52A is cut from circular substrate 50 using saw 56. As shown in FIG. The row 52A is then secured, for example, to a transport tool 90 with adhesive, see FIG. 5, leaving the end face 59 of the row 52A exposed. The end face 59 of row 52A is then ground flat. Further processing of the sensor leads to an embodiment as shown in FIG. 6A.

Referring now to FIG. 6A, end faces 59 of row 52A are ground flat and a magnetic gap layer 92 is formed. The end face of the horizontal portion of the second pole piece is exposed and deposited with a vertical portion 94 . The second pole piece, indicated by reference numeral 96, comprises its horizontal portion 72 and its vertical portion 94. Thus, sensor portion 24 includes second pole piece 96 integrally formed with magnetic gap 92 , see FIG. 4 , first pole piece layer 62 and magnetic element 64 . After vertical portion 94 is formed, protective layer 98 is deposited. The row 52A structure is now completed and ready to be divided into individual assemblies 22 for disks 12, see FIG. As shown in FIG. 3, the saw 58 divides the row 52A containing the plurality of fabricated sensors into a number of individual units. A second type of vertical section for the second pole piece 96 is shown in Figure 6B.

Referring now to FIG. 6B, the magnetic gap layer 92 is also deposited first on the end surface 59 of the row 52A. The magnetic gap layer 92 is then ground to form an angle X with the vertical direction, exposing the end of the horizontal portion 72 of the second pole piece. A layer of deposited magnetic material forms vertical portion 99 . A second pole piece, indicated by reference numeral 96 , includes a horizontal portion 72 and a vertical portion 99 . Thus, sensor portion 24 includes second pole piece 96 integrally formed with magnetic gap 92 , first pole piece layer 62 and magnetic element 64 . After the vertical sections 99 have been formed, a protective layer 98 is deposited as described above, as described for FIGS.

Referring again to FIG. 4, the fabricated assembly 22, including the sensor portion 24 and the suspension portion 26, is released from the substrate 50 by dissolving the separation layer 60. As shown in FIG. The separation layer 60 may be copper-plated. Another separation layer material may be tungsten. For example, ammonium persulfate can be used to easily remove the copper separation layer without causing corrosion to the aluminum oxide substrate usually used in the sensor manufacturing process. Once the assembly is made, it is readily applicable to hard disk readout systems, as will be apparent to those skilled in the art.

Circular substrate 50 may be any suitable material known in the art. Substrate 50 is not required to be alumina-titanium-carbide or silicon. Separation layer 60, which may be, for example, a conductive material, serves as a seed or plating base for a subsequently deposited layer, such as the first pole piece layer 62 of the sensor. The conductive material is preferably copper plating, but could also be gold or other suitable conductor. The wire 78 is routed along the suspension section 26 to the conductor plug 80 . The conductors should consist of two flat thin wires forming the stripline, since the suspended section 26 is thin and the required stress symmetry is compatible with the stripline design. Suspension section 26 is preferably fabricated by depositing aluminum oxide as first and second insulating layers 66 and 62 . The conductive plugs 80 and conductive bumps 48 are fabricated using standard conductive plug and conductive bump fabrication techniques to form the thin film sensor-suspension assembly, as is known in the art. The sensor with cladding 98 may be encapsulated with thick deposited alumina. For example a thin layer of aluminum oxide may form the magnetic gap 92 and for example permalloy may be used as the magnetic material forming the pole piece portion of the sensor. The shape of the pole piece of the sensor is shown in FIG. 7 . In order to show the preferred shape of the magnetic part of the sensor of the present invention, the figures show the coil and the sensor.

Referring now to FIG. 7, a preferred embodiment of the present invention includes a sensor that incorporates the advantages of Jones, Jr. et al., U.S. Patent 4,190,872, issued February 26, 1980, and assigned to the assignee of the present invention . The sensor comprises a first pole piece layer 62 magnetically connected by a magnetic element 64 to a horizontal portion 72 of a second pole piece at a rear air gap 100 . The vertical portion 94 of the second pole piece is magnetically connected to its horizontal portion 72 and is separated from the first pole piece 62 by a magnetic gap 92 . The width of the first pole piece is greater at its rear air gap 100 than at its pole head 102 . Likewise, the horizontal portion of the second pole piece has a greater width at the rear air gap 100 than at the end 104 where the vertical portion 94 joins. Vertical portion 94 is greater than the width of its pole head 106 at the end that is connected with the end 104 of pole piece 72, and the preferred shape of sensor is as shown in Figure 7, and it has narrow pole head structure, but has avoided magnetic field line along pole. Saturation of slices.

Although the present invention has been shown in detail and described in detail with reference to preferred embodiments, it should be understood that, without departing from the spirit and scope of the present invention, those skilled in the art can follow the embodiments described in U.S. Patent 4,190,872 The sensor is fabricated on a substrate in the manner described above, but other structures can also be used without departing from the scope of the present invention. The substrate may be made of the materials described in the subject matter of US Patent 4,251,841 to Jacobs et al., entitled "Magnetic Head Slider" and assigned to the assignee of the present invention. The suspending part according to the preferred embodiment may be a double-layer material of polyimide material and a metal layer deposited thereon, so that it has sufficient elasticity and rigidity required by the suspending member. Care must be taken, provided the single layer material is of suitable thickness and strength. It is also possible to manufacture the suspension from a single layer of material. It should also be understood that there are many conductive materials that can be used for conductive circuits and sensor leads. Copper and gold are preferred, but many other materials are suitable as is well known in the art. Although air bearing suspension is described here, the invention also includes contact recording, where the suspension device brings the sensor into contact with the recording medium. The following claims describe the scope of the invention claimed.

Claims (8)

1. A combined thin-film head sensor and suspension system for longitudinal recording, comprising: a first horizontal thin-film pole piece with pole head; a vertical thin film magnetic gap formed at the pole head of said first pole piece; a second thin film pole piece having a vertical portion having a pole head adjacent to said magnetic gap and a horizontal portion adjacent to and parallel to said first pole piece but not connected to said first pole piece magnetic sheet insulation, said first and second pole pieces being magnetically connected at a backgap region and magnetically insulated at their pole tips by said magnetic gap; a thin film coil electrically insulated from but energized by said first and second pole pieces and encircling a horizontal portion of said second pole piece; It is characterized by: said first and second pole pieces are configured to have a wider surface at their back gap region and a narrower surface at their head; a suspended layer of a film layer of elastic material covering at least a horizontal portion of said second pole piece and electrically and magnetically insulated from said second pole piece and said coil, said elastic material extending beyond the backlash region ;as well as The vertical portion of the second pole piece has a substantially vertical portion on an end adjacent to the magnetic gap layer and a portion on a second end offset from the substantially vertical portion, which is aligned with the horizontal portion of the second pole piece touch. 2. The combined thin-film magnetic head sensor and suspension system according to claim 1, characterized in that: the pole head of the first pole piece is horizontal and perpendicular to the vertical part of the second pole piece; The first pole piece has a downwardly sloped portion adjacent to the head of the first pole piece; a vertical thin film magnetic gap at said magnetic gap, having opposing first and second vertical thin film surfaces; The first and second vertical film surfaces are formed by a film deposition process without grinding; The first thin film surface of the thin film magnetic gap layer is in direct contact with the pole head of the first horizontal thin film pole piece; the second thin film pole piece has a vertical portion having a pole head in direct contact with the second vertical thin film surface of the thin film magnetic gap layer; The width of the first pole piece narrows from the inclined portion to the pole head. 3. The combined thin-film magnetic head sensor and suspension system according to claim 1 or 2, further comprising a conductor connected to said coil, said conductor being included in said suspension layer. 4. A combined thin film magnetic head sensor and suspension system according to claim 1 or 2, further comprising a wear-resistant layer covering the outside of said suspension layer and the first pole piece adjacent to its pole head. 5. A disk drive assembly comprising: a shell; a magnetic disk mounted in said housing and having means for storing data in tracks thereon; means for rotating the disk within the housing; an actuator arm mounted within the housing with a free end operatively abutting a track on the magnetic disk; positioning means for abutting said actuator arm on each track on said disk; and A combined thin-film head sensor and suspension system for longitudinal recording, including: a first horizontal thin-film pole piece with pole head; a vertical thin film magnetic gap formed at the pole head of said first pole piece; a second thin film pole piece having a vertical portion having a pole head adjacent to said magnetic gap and a horizontal portion adjacent to and parallel to said first pole piece but not connected to said first pole piece magnetic sheet insulation, said first and second pole pieces being magnetically connected at a backgap region and magnetically insulated at their pole tips by said magnetic gap; a thin film coil electrically insulated from but energized by said first and second pole pieces and encircling a horizontal portion of said second pole piece; It is characterized by: said first and second pole pieces are configured to have a wider surface at their back gap region and a narrower surface at their head; a suspended layer of a film layer of elastic material covering at least a horizontal portion of said second pole piece and electrically and magnetically insulated from said second pole piece and said coil, said elastic material extending beyond the backlash region ;as well as The vertical portion of the second pole piece has a substantially vertical portion on an end adjacent to the magnetic gap layer and a portion on a second end offset from the substantially vertical portion, which is aligned with the horizontal portion of the second pole piece touch. 6. The disk drive assembly according to claim 5, wherein in said combined thin-film magnetic head sensor and suspension system, the pole head of the first pole piece is horizontal and perpendicular to the vertical part of the second pole piece; The first pole piece has a downwardly sloped portion adjacent to the head of the first pole piece; a vertical thin film magnetic gap at said magnetic gap, having opposing first and second vertical thin film surfaces; The first and second vertical film surfaces are formed by a film deposition process without grinding; The first thin film surface of the thin film magnetic gap layer is in direct contact with the pole head of the first horizontal thin film pole piece; the second thin film pole piece has a vertical portion having a pole head in direct contact with the second vertical thin film surface of the thin film magnetic gap layer; The width of the first pole piece narrows from the inclined portion to the pole head. 7. A method for manufacturing a combined thin-film magnetic head sensor and a suspension system, characterized in that it comprises the following steps: Prepare a circular substrate; forming an inclined contact area on the circular substrate; forming a separation layer on the substrate; forming a first pole piece of magnetic material on the formed separation layer; forming a contoured backlash element on said formed first pole piece; forming a wear-resistant layer on the formed first pole piece, and extending a certain distance for the suspension section; forming a magnetic and electrical insulating layer on the formed wear-resistant layer covering at least the first pole piece layer, and extending a certain distance as the first suspension layer for the suspension section; forming a first half-film coil of conductive material on said formed insulating layer; forming a first electrically insulating layer covering at least one half of said formed thin-film coil; forming a horizontal portion of a magnetic material constituting a second pole piece layer pattern on the formed insulating layer; forming a second electrically insulating layer covering at least the patterned second pole piece layer; forming a second half-film coil of conductive material on the formed second electrical insulating layer and electrically connecting it to the fabricated first half-coil; forming a magnetic and electrical insulating layer on the formed second half-film coil, and extending a certain distance as a second suspension layer for the suspension section; forming a magnetic gap layer of magnetically insulating material on the free end of the assembly produced by the forming step and covering the end of the formed first pole piece layer opposite to said formed rear air gap layer; A vertical portion of a patterned second pole piece layer of magnetic material is formed on said formed magnetic gap layer, the vertical portion having a substantially vertical portion on an end adjacent to said magnetic gap layer and at an offset from substantially a portion on the second end of the vertical portion in contact with the horizontal portion of said second pole piece; forming a protective layer to cover the vertical part of the pole piece; Dissolving the separation layer to separate the formed contact region and the formed first pole piece layer from the substrate; The steps described above configure said first and second pole pieces to have a wider surface at their backspace regions and a narrower surface at their pole tips. 8. The method for manufacturing a combined thin-film magnetic head sensor and suspension system according to claim 7, characterized in that it comprises the steps of: forming a first conductor layer of conductive material on the formed insulating layer extending for a certain distance as a suspension section, and electrically connecting with the formed first half-coil; forming a second conductor layer of electrically conductive material on said formed second electrically insulating layer extending a distance to serve as a suspended section, and electrically connecting to said formed second half-coil; and Conductive bumps for the formed first and second conductor layers are formed adjacent to ends of the suspended segments opposite to the formed first and second pole pieces.

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