Nesting Disk Separator Plates for Hard Disk Drives
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Solution Overview
Problem
The existing methods for manufacturing disk separator plates for hard disk drives are costly and inefficient, requiring excessive raw materials and secondary manufacturing operations, while struggling to achieve precise dimensional control and smooth surface finishes.
Innovation Solution
The method involves stamping and then extruding or forming offsets to desired dimensions, eliminating the need for additional alignment pins and holes, and allowing for compact designs by using folded or extruded offsets that nest for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods (casting, extrusion, injection molding) are used to produce disk separator plates, then the plates can be manufactured, but the manufacturing cost increases and dimensional precision decreases
Solution Approach 1:
The offset structure is segmented into multiple functional zones: a first offset portion extending from the main body, a second offset portion extending from the first offset portion, and a third offset portion extending from the second offset portion. This segmentation allows each portion to be optimized independently for its specific function, achieving precise dimensional control while simplifying the overall manufacturing process through stamping operations.
Solution Approach 2:
The patent transitions from traditional three-dimensional casting or extrusion processes to a two-dimensional stamping process followed by folding. The offset structures are created by folding the stamped plate at specific angles rather than building them up in multiple dimensions, which simplifies manufacturing while maintaining precise dimensional control.
2Manufacturing precision
If traditional offset structures are used with alignment pins and holes, then alignment can be achieved, but the device complexity and material usage increase
Solution Approach 1:
The alignment function is merged into the offset structure itself. The nested offset portions (first, second, and third offset portions) inherently provide alignment through their geometric configuration and nesting relationship, eliminating the need for separate alignment pins and holes. This integration reduces structural complexity while maintaining precise alignment.
Solution Approach 2:
The offset structures are designed to nest within each other in a hierarchical manner. The second offset portion nests within the first offset portion, and the third offset portion nests within the second offset portion. This nesting arrangement provides self-alignment and precise positioning without requiring additional alignment components.
3Productivity
If plastic injection molding is used to manufacture separator plates, then production can be achieved, but voids, anisotropies, and surface finish defects occur
Solution Approach 1:
The patent adopts a stamping process that uses a disposable or replaceable steel stamping die rather than a complex injection molding system. The stamping process creates a flat plate with predetermined fold lines that is then folded to form the offset structures, avoiding the voids and anisotropies inherent in injection molded plastic parts while maintaining high production capability.
Data Source
AI summary
A hard disk drive with a multiple disk stack normally utilizes disk separator plates near the disk surfaces to reduce wind induced vibrations in the disks and the read/write heads. The manufacturing methods currently used to make these separator plates, metal casting and machining, or injection molded plastic, or extruding and machining, or cold forging tends to be expensive and creates unwanted weight and bulk without the desired precision. Stamping disk separator plates from metal provides exceptional dimensional control at reduced cost, but cannot readily provide the thicknesses required. Stamping and extruding the offsets, or stamping and folding the offsets, is a manufacturing process that provides the required dimensions for the offsets, and dimensional control and reduced cost.