Disk Drive Headlift With Formed Rail Offset and Coining
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Solution Overview
Problem
There is a need for improved disk drive headlifts that are relatively stiff and efficient manufacturing methods for these components, as existing technologies do not adequately address the requirements for stiffness and manufacturing efficiency.
Innovation Solution
A disk drive head suspension headlift component is formed from a single piece of metal with a beam region, a trough-shaped headlift tab, and an offset region, where the headlift tab is z-height spaced from the beam region, and crimps are included in the side rails to enhance stiffness and manufacturing efficiency, using a method that involves coining the headlift tab and forming the offset region and side rails through mechanical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional multi-piece construction methods are used for headlifts, then manufacturing flexibility is maintained, but manufacturing efficiency and structural integrity deteriorate due to multiple assembly steps and potential weak joints
Solution Approach 1:
The patent merges multiple separate components (beam region, offset region, and headlift tab) into a single integrated headlift component formed from one piece of metal. This eliminates the need for separate manufacturing and assembly steps for each component, directly improving manufacturing efficiency while reducing assembly complexity and potential weak joints at connection points.
2Ease of manufacture
If headlifts are designed for ease of manufacture, then manufacturing simplicity is improved, but structural stiffness deteriorates due to simplified geometries and fewer reinforcing features
Solution Approach 1:
The patent applies local quality by introducing crimps specifically at the side rails where structural reinforcement is most needed (at the intersections with the offset region and headlift tab). These localized geometric modifications provide targeted stiffness enhancement in critical areas without requiring complex geometries throughout the entire component, thus maintaining ease of manufacture while improving structural performance.
3Reliability
If z-height offset is introduced between beam region and headlift tab, then headlift functionality is improved, but manufacturing complexity increases due to additional forming steps and precision requirements
Solution Approach 1:
The patent implements the z-height offset through preliminary action by forming the offset region and establishing the vertical spacing between the beam region and headlift tab during the initial single-piece forming process. This preliminary formation of the offset geometry ensures precise z-height positioning is built into the component structure itself, eliminating the need for subsequent precision adjustment steps and maintaining manufacturing simplicity.
4Strength
If crimps are added to side rails, then headlift stiffness is improved, but manufacturing complexity increases due to additional forming operations
Solution Approach 1:
The patent merges the crimp formation operation with the main headlift forming process. The crimps at the side rails are created as integral features during the single-piece forming operation, combining multiple functions (structural reinforcement and component formation) into one manufacturing step. This eliminates the need for separate crimping operations, thus improving stiffness without significantly increasing manufacturing complexity.
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 solution provides a stiff headlift component with an efficient manufacturing process, improving the structural integrity and production efficiency of disk drive head suspensions by utilizing a single-piece metal construction and specific mechanical forming techniques.
Implementation Method 1
coining a trough-shaped headlift tab, forming rails on a beam region and forming a z-height offset region
Implementation Method 2
forming rails on a beam region and forming a z-height offset region having a major surface and transitional height side rails
Data Source
AI summary
A disk drive head suspension headlift formed from a single piece of stainless steel includes a beam region, lift tab and offset region between the beam region and lift tab. The beam region has a major surface and formed side rails. The lift tab is a coined, trough-shaped member at a z-height spaced from the major surface of the beam region. The offset region has a major surface and side rails that transition in height between the side rails of the beam region and the lift tab.