Disk Drive Head Suspension Limiter Fold-Over Assembly
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Solution Overview
Problem
Existing disk drive head suspension limiters either have low engagement and tight tolerance gaps, making them prone to unhooking, or require complex multi-axis merge processes that complicate manufacturing and make it difficult to control limiter gaps.
Innovation Solution
A limiter design with high engagement and tight gap specifications is achieved by forming a tab and hook structure that allows for assembly without multi-axis merge operations, using a fold-over limiter with an L-shaped engaging structure and a motion-limited region, where the hook overlaps the engaged portion significantly, and can be manufactured using z-direction motion only.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If limiters are formed after component assembly, then manufacturing is easier, but limiter engagement is low making them prone to unhooking
Solution Approach 1:
The limiter structure is prepared in advance on the first suspension component before final assembly, with the engaging structure pre-formed to receive the second component. This preliminary preparation enables easy assembly while maintaining high engagement through the pre-configured geometric interlocking features.
2Reliability
If limiters are formed before component assembly, then limiter engagement is high, but the merge process requires motion along more than one axis complicating manufacturing
Solution Approach 1:
The limiter is divided into separate functional segments: the engaging structure on the first suspension component and the second component with corresponding features. This segmentation allows each part to be manufactured independently using simple z-direction motion, then assembled together to achieve high engagement without complex multi-axis merging.
3Reliability
If merged limiters are used, then limiter engagement is high, but it is more difficult to control the limiter gap
Solution Approach 1:
A tab structure serves as an intermediary element between the engaging structure and the second component. The tab provides a reference surface that mediates the positioning relationship, enabling precise control of the limiter gap while maintaining high engagement through the geometric interlocking of the engaging structure with the second component.
Data Source
AI summary
A method for manufacturing a disk drive head suspension including a load beam, a flexure and a limiter for restricting the range of motion of the flexure with respect to the load beam. The load beam includes an aperture and an engaged portion adjacent to the aperture. The flexure, in an unformed state, includes a slider mounting region and a generally planar engagement structure extending from the slider mounting region. The engagement structure includes a tab portion extending from the slider mounting region and a hook portion extending from the tab portion. During a first forming operation the hook portion is bent around a tooling die to a ninety degree angle with respect to the tab portion. The flexure is then welded to the load beam with the hook portion extending into the aperture. During a second forming operation the tab portion is bent around a tooling die to a ninety degree angle with respect to the slider mounting region. The second forming operation causes the hook to extend over the engaged portion of the load beam. The first and second forming operations can be performed with tooling moving only in a z-direction.