Full-Rail Suspension Shearing Fracture Detab
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Solution Overview
Problem
Conventional methods for forming rails on head suspension load beams in disk drives often require multiple steps, which can damage or deform the load beam and affect its resonance and shock performance due to uneven aerodynamic forces and the need to separate components from a carrier strip without altering their precise tolerances.
Innovation Solution
A method involving a semi-finished suspension product with a load beam and a beam carrier strip connected by tabs with a detaching region of lower shear strength, allowing full side rails to be formed in a single step by applying a shear load to the tabs, thereby avoiding deformation and improving resonance and shock performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple steps are used to form rails on the load beam, then the rails can be formed, but the load beam may be damaged or deformed
Solution Approach 1:
The rail profile is pre-formed on the carrier strip before the load beam is attached. This preliminary formation of rails eliminates the need for subsequent forming steps that would require manipulating the load beam, thereby preventing damage or deformation to the load beam while still achieving the desired rail structure
Solution Approach 2:
The manufacturing process is segmented into distinct phases: first forming rails on the carrier strip, then attaching the load beam. This segmentation allows the rail formation to occur on a separate component (carrier strip) that is more tolerant of forming operations, protecting the load beam from damage
2Ease of operation
If tabs are used to connect the load beam to the carrier strip, then the components can be easily handled, but the tabs must be separated later which risks altering precise tolerances
Solution Approach 1:
The tab structure incorporates a localized reduced-thickness region that creates a controlled weak point. This local quality change allows the tab to be strong enough for handling during manufacturing, yet designed to fracture cleanly at a specific location, ensuring that the separation does not affect the precise tolerances of the load beam or carrier strip
Solution Approach 2:
The tab acts as an intermediary connecting element with a designed failure point. The reduced-thickness region serves as a mediator that allows easy separation while protecting the main components. The tab's structured design ensures it fails in a controlled manner that preserves the integrity and tolerances of both the load beam and carrier strip
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the resonance and shock performance of the load beam by forming full side rails in a single step, reducing strain on the load beam and minimizing structural and cosmetic impacts during fabrication, while maintaining precise tolerances.
Implementation Method 1
A shear load is applied to the one or more tabs to cause the one or more tabs to fracture at the detaching region
Data Source
AI summary
A multi-piece head suspension assembly is manufactured from a semi-finished suspension product. The semi-finished suspension product includes a load beam having two side edges, a distal end, and a proximal end opposite the distal end. The semi-finished suspension product also includes a beam carrier strip connected to the proximal end by one or more tabs. Each tab includes a detaching region that has a lower shear strength than other regions of the tab. Rails are formed on the side edges of the load beam, and the semi-finished suspension product is attached to a hinge assembly at the proximal end of the load beam. A shear load is applied to the one or more tabs to cause the one or more tabs to fracture at the detaching region.