Disk Drive Head Suspension Load Point Dimple Plating

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Solution Overview

Problem

Existing load point dimples in head suspensions for disk drives suffer from deformation and positional tolerance issues during assembly, leading to inaccurate positioning and increased stress on the surface.

Innovation Solution

A method for manufacturing a disk drive head suspension flexure with a load point dimple, where an aperture is etched into a spring metal member, and metal is plated to form a load point with precise dimensions, using photoresist masks and electroplating techniques to ensure accurate placement and minimal stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If load point dimples are formed by forming or etching processes, then the load point can be created on the spring metal member, but deformation and positional tolerance issues occur during assembly leading to inaccurate positioning

Engineering Contradiction:

Improveload point positioning accuracyVSAvoidassembly deformation

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The load point is formed by plating metal into an etched aperture during the manufacturing process itself, before assembly occurs. This preliminary formation of the load point with precise dimensions eliminates subsequent deformation issues that would affect positioning accuracy during assembly operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical forming processes with electrochemical etching and electroplating processes. The aperture is etched chemically rather than mechanically formed, and the load point is built up through controlled metal deposition rather than mechanical shaping, thereby avoiding mechanical deformation and associated positional tolerance accumulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If load points are formed by fixing a spherical ball between the flexure and load beam, then the load point structure can be created, but stack-up of positional tolerances increases reducing manufacturing precision

Engineering Contradiction:

Improveload point structure creationVSAvoidload point positioning

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent merges the aperture formation and load point creation into a single integrated process sequence. The aperture is etched and the load point is plated in the same manufacturing run, eliminating the need for separate assembly operations that would introduce additional positional tolerance stack-up.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical process of fixing a spherical ball is replaced with an electrochemical process where metal is plated into an etched aperture. This substitution eliminates the mechanical alignment and positioning steps required for ball fixation, thereby reducing positional tolerance accumulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If conventional forming processes are used to create load point dimples, then the dimple can be formed on the surface, but increased stress is imposed on the surface reducing reliability

Engineering Contradiction:

Improvedimple formationVSAvoidsurface stress

Core Design Contradiction:

Manufacturing precisionVSStress or pressure

Solution Approach 1:

The patent replaces mechanical forming processes with chemical etching and electroplating. The aperture is created through chemical dissolution rather than mechanical compression, and the load point is built up through controlled metal deposition rather than mechanical shaping, thereby avoiding the high surface stresses associated with conventional forming.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical-chemical parameters of the manufacturing process from mechanical high-stress forming to low-stress chemical etching and controlled electroplating. This parameter change allows precise dimple formation while maintaining surface integrity and minimizing stress induction.

Inventive Principle:

Principle #35Parameter changes

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

The method allows for precise location and reduced stress on the surface, enhancing the accuracy and reliability of the load point dimple, thereby improving the positioning and functionality of the head slider in disk drives.

Implementation Method 1

A photoresist mask having an opening with load point-defining side walls and a load point diameter is formed over a portion of the spring metal member including the aperture

Methodology Applied

Scientific EffectPhotoresist masking: Photography

Implementation Method 2

Metal is plated onto the spring metal member and into the aperture in the opening to form a load point having a load point diameter on the spring metal member

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS8881375B2Method for manufacturing a disk drive head suspension

Publication Date: 2014.11.11 HUTCHINSON TECH INC

AI summary

A method for manufacturing a disk drive head suspension having a plated load point dimple. An aperture is etched into the spring metal member. A photoresist mask having an opening with load point-defining side walls and a load point diameter is formed over a portion of a spring metal member including the aperture. Metal is plated onto the spring metal member and into the aperture in the opening to form a load point having the load point diameter on the spring metal member.