Disc Device Suspension Positioning via Convex-Concave Interlock
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Solution Overview
Problem
Existing manufacturing methods for disc device suspensions face challenges in accurately positioning the flexure with respect to the load beam, leading to potential misalignment and conductivity errors due to interference and mismatch in materials like stainless steel.
Innovation Solution
A manufacturing method involving a load beam blank with a convex portion and a flexure blank with a softer metal conductor layer, where the convex portion is inserted into an opening with a specific design to ensure precise alignment, including a metal base, conductor layer, and insulating layers, allowing for accurate positioning and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a dome-like convex positioning part and a simple hole engaging part are used, then the manufacturing process is simple, but the positioning accuracy deteriorates due to interference and material mismatch
Solution Approach 1:
The patent applies local quality by making the conductor layer (which forms the engaging part) have different material properties than the base. Specifically, the conductor layer is made of a softer metal material than the base, allowing it to deform and conform to the convex positioning part during engagement, thereby achieving both ease of manufacture and high positioning accuracy without interference issues
Solution Approach 2:
The patent uses composite materials by constructing the flexure as a multi-layer structure with a base and a conductor layer made of different metal materials. The conductor layer is specifically chosen to be softer than the base, creating a composite structure that combines the structural integrity of the base with the conformability and engagement capability of the softer conductor layer, resolving the positioning accuracy problem
Data Source
AI summary
A manufacturing method of a disc device suspension includes forming a load beam blank including the load beam and a first frame continuous to the load beam, forming a flexure blank including the flexure and a second frame continuous to the flexure, forming a convex portion in the first frame, forming an opening in the second frame in a position corresponding to the convex portion to receive the convex portion, overlapping the load beam blank with the flexure blank to insert the convex portion into the opening, fixing the flexure to the load beam, and separating the load beam from the first frame and the flexure from the second frame after the fixing.