Magnetoresistive stack/structure and method of manufacturing same

1. A method of manufacturing a magnetoresistive stack/structure from: (i) a first magnetic region including one or more layers of magnetic material, (ii) a dielectric layer disposed over the first magnetic region, (iii) a second magnetic region including one or more layers of magnetic material, wherein the second magnetic region is disposed over the dielectric layer, the method comprising:

etching through the second magnetic region to (i) provide sidewalls of the second magnetic region and (ii) expose a surface of the dielectric layer;

depositing a first encapsulation layer on the sidewalls of the second magnetic region and over the exposed surface of the dielectric layer;

etching (i) the first encapsulation layer which is disposed over the exposed surface of the dielectric layer using a first etch process and (ii) re-deposited material disposed on the surface of the dielectric layer using a second etch process, wherein, after etching the first encapsulation layer and the re-deposited material, a portion of the first encapsulation layer remains on the sidewalls of the second magnetic region;

depositing a second encapsulation layer: (i) on the first encapsulation layer which is disposed on the sidewalls of the second magnetic region and (ii) over the exposed surface of the dielectric layer;

etching (i) the second encapsulation layer which is disposed over the exposed surface of the dielectric layer and (ii) through the exposed surface of dielectric layer to form a tunnel barrier and provide sidewalls thereof; and

etching the first magnetic region to provide sidewalls thereof after etching through the exposed surface of dielectric layer.

2. The method of claim 1 wherein

the second etch process is a physical etch.

3. The method of claim 2 wherein the first etch process is a reactive ion etch.

4. The method of claim 2 wherein the second etch process is a sputter etch or an ion milling etch.

5. The method of claim 2 wherein:

the first etch process is a reactive ion etch; and

the second etch process is a sputter etch or an ion milling etch.

6. The method of claim 1 wherein the first encapsulation layer is: (i) an aluminum oxide and/or an aluminum nitride having a thickness of between 0.5 and 50 Angstroms, or (ii) a silicon oxide, a silicon nitride and/or a TEOS having a thickness of between 50 and 300 Angstroms.

7. The method of claim 1 wherein:

the material of the first encapsulation layer is different from the material of the second encapsulation layer.

8. A method of manufacturing a magnetoresistive stack/structure from: (i) a first magnetic region including one or more layers of magnetic material, (ii) a dielectric layer disposed over the first magnetic region, (iii) a second magnetic region including one or more layers of magnetic material, wherein the second magnetic region is disposed over the dielectric layer, the method comprising:

etching through the second magnetic region to (i) provide sidewalls of the second magnetic region and (ii) expose a surface of the dielectric layer;

depositing a first encapsulation layer on the sidewalls of the second magnetic region and on re-deposited material that is disposed on portions of the exposed surface of the dielectric layer, wherein the re-deposited material includes one or more magnetic materials of the second magnetic region;

etching (i) the first encapsulation layer which is disposed over the exposed surface of the dielectric layer using a first etch process and (ii) the re-deposited material disposed on the surface of the dielectric layer using a second etch process, wherein, after etching the first encapsulation layer and the re-deposited material, a portion of the first encapsulation layer remains on the sidewalls of the second magnetic region;

depositing a second encapsulation layer: (i) on the first encapsulation layer which is disposed on the sidewalls of the second magnetic region and (ii) over the exposed surface of the dielectric layer;

etching (i) the second encapsulation layer which is disposed over the exposed surface of the dielectric layer and (ii) through the exposed surface of dielectric layer to form a tunnel barrier and provide sidewalls thereof; and

etching the first magnetic region to provide sidewalls thereof after etching through the exposed surface of dielectric layer.

9. The method of claim 8 wherein the second etch process includes

a sputter etch or an ion milling etch.

10. The method of claim 9 wherein the first etch process is a reactive ion etch.

11. The method of claim 8 wherein the first encapsulation layer is: (i) an aluminum oxide and/or an aluminum nitride having a thickness of between 0.5 and 50 Angstroms, or (ii) a silicon oxide, a silicon nitride and/or a TEOS having a thickness of between 50 and 300 Angstroms.

12. The method of claim 8 wherein the first etch process is a reactive ion etch.

13. The method of claim 12 wherein etching the second encapsulation layer includes etching the second encapsulation layer using the first etch process.

14. The method of claim 8 wherein the second etch process is a physical etch.

15. The method of claim 8 wherein:

the material of the first encapsulation layer is different from the material of the second encapsulation layer.

16. The method of claim 8 wherein the second encapsulation layer includes an aluminum oxide, a silicon oxide, a silicon nitride, a TEOS, or an aluminum nitride.

17. The method of claim 1 wherein the second encapsulation layer is: (i) an aluminum oxide and/or an aluminum nitride having a thickness of between 0.5 and 50 Angstroms, or (ii) a silicon oxide, a silicon nitride and/or a TEOS having a thickness of between 50 and 300 Angstroms.

18. The method of claim 1 wherein the second encapsulation layer includes an aluminum oxide, a silicon oxide, a silicon nitride, a TEOS, or an aluminum nitride.

19. The method of claim 18 wherein the first encapsulation layer includes an aluminum oxide, a silicon oxide, a silicon nitride, a TEOS, or an aluminum nitride.

20. The method of claim 1 wherein:

the second etch process is a physical etch, and

etching the second encapsulation layer includes etching the second encapsulation layer using the first etch process.