Fracture Portion Layout for Low-Vibration Suspension Tearing
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Solution Overview
Problem
The existing methods for separating suspension components from a frame in disk drives face challenges such as high accuracy requirements, high costs, burr formation, and vibration issues during the tearing process, which affect the quality of the fracture portion and yield of the suspension.
Innovation Solution
A plate material with a fracture portion comprising thin portions of varying widths and openings, arranged in a specific pattern to facilitate controlled tearing, allowing for efficient separation with reduced vibration and improved yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cut portion is relatively thick to maintain frame strength, then the strength to support the suspension is improved, but strong vibration occurs during tearing which reduces manufacturing precision
Solution Approach 1:
The fracture portion is segmented into multiple thin portions arranged in the second direction (width direction of plate material). These thin portions are distributed across the fracture region to enable controlled tearing while maintaining overall frame strength through the remaining thicker portions. This segmentation allows the structure to tear in a controlled manner without excessive vibration.
Solution Approach 2:
The plate material exhibits non-uniform thickness distribution: thin portions are localized at specific regions within the fracture portion to facilitate easy tearing, while other regions maintain sufficient thickness for structural strength. This local variation in quality (thickness) allows simultaneous achievement of tearability and structural integrity.
2Manufacturing precision
If all thin portions are made thin to suppress vibration during tearing, then tearing quality is improved, but the strength to support the suspension is reduced causing increased vibration during transportation
Solution Approach 1:
Instead of uniformly thinning the entire fracture portion, only specific localized thin portions are created at strategic positions. These segmented thin regions are sufficient to initiate and guide the tearing process, while the rest of the structure maintains adequate thickness for strength.
Solution Approach 2:
The plate material is designed with spatially varying thickness: thin portions are placed only where needed for tear initiation and propagation, while adjacent regions maintain greater thickness for structural support. This local differentiation resolves the contradiction between tearability and strength.
3Manufacturing precision
If high accuracy is required for clearance between punch and lower die to achieve clean separation, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The thin portions are pre-formed in the plate material before the tearing operation. This preliminary preparation creates predetermined weak points that guide the tearing process, eliminating the need for high-precision clearance control during the actual separation operation. The tearing becomes a simple tensile process rather than a precision cutting operation.
4Ease of manufacture
If the fracture portion is made thin to enable easy tearing, then ease of manufacture is improved, but the strength to support the suspension is reduced
Solution Approach 1:
The fracture portion contains multiple thin portions distributed in the width direction, creating multiple predetermined tear initiation points. This segmentation enables easy tearing through tensile force while the distributed arrangement ensures that not all regions are equally weakened, preserving overall structural integrity.
Solution Approach 2:
Thin portions are localized only within the fracture region where tearing is needed, while the rest of the plate material maintains sufficient thickness for strength. This spatial differentiation of thickness allows easy tearing at the fracture portion while maintaining frame strength elsewhere.
Data Source
AI summary
A plate material has a first portion, a second portion, and a fracture portion connecting the first portion and the second portion, and is separated into the first portion and the second portion by tearing the fracture portion. The first portion and the second portion are arranged in a first direction. The fracture portion has thin portions arranged in a second direction crossing the first direction. Widths in the second direction of the thin portions are different from each other.