Head Suspension Offset Structure with Segmented Voids
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Solution Overview
Problem
Thinner head suspensions in disk drives face challenges with material thinning and stretching during offset formation, leading to potential fractures and a need for improved structural integrity in load point dimples manufactured from thin stock.
Innovation Solution
The implementation of an offset structure with elongated voids and links extending in radial and circumferential directions, which are formed using photolithography and mechanical processes to minimize material thinning and enhance structural integrity, allowing the offset to extend out of the plane of the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional punch press forming is used to create offset structures, then the offset can be formed with a convex surface, but the thin material surrounding the base of the offset and on the resulting surface experiences stretching and thinning that can lead to fracture
Solution Approach 1:
The patent divides the continuous material around the offset into discrete segments by introducing elongated voids. These voids segment the material into links that surround the offset, preventing continuous stretching and thinning while maintaining structural integrity. The segmented structure allows the offset to be formed without the material undergoing harmful deformation.
Solution Approach 2:
The patent introduces a porous structure with elongated voids surrounding the offset. This porous configuration allows the material to accommodate the offset formation without excessive stretching. The voids act as stress relief zones that prevent material thinning and potential fracture while maintaining the overall structural integrity of the thin load beam or flexure.
2Length of moving object
If the head suspension is made thinner to meet design requirements, then the device becomes more compact, but the material becomes more susceptible to thinning and fracture during offset formation
Solution Approach 1:
By segmenting the continuous material into discrete links separated by elongated voids, the patent prevents stress propagation through the thin material. This segmentation allows thinner materials to withstand the forming process without fracture, as each link can deform independently without compromising the entire structure's integrity.
Solution Approach 2:
The porous structure with strategically placed elongated voids provides stress relief zones that prevent catastrophic failure in thin materials. The voids allow the thin material to accommodate forming stresses through localized deformation rather than continuous stretching, thereby maintaining reliability even as thickness is reduced for compactness.
3Manufacturing precision
If precision forming processes are used to create the offset, then the offset shape can be controlled, but regions on the surface of the offset and around the base still experience thinning
Solution Approach 1:
The segmentation of material into discrete links separated by voids prevents stress propagation during precision forming. Each link can be precisely formed without causing cumulative thinning effects, as the voids isolate the deformation zones. This allows precise control of offset shape while preventing harmful material thinning.
Solution Approach 2:
The porous structure with elongated voids provides stress relief zones that prevent material thinning during precision forming operations. The voids allow the material to accommodate forming stresses without excessive stretching, enabling precise offset formation while maintaining adequate material thickness and structural integrity.
Data Source
AI summary
Head suspension offset structures and methods of manufacture. The offset structure includes an offset extending out of a plane of a surface on which it is formed and a plurality of elongated voids and elongated links surrounding the offset. The links extend between the offset and the surface in both radial and circumferential direction. At least a portion of the elongated links and voids extend out of the plane of the surface, minimizing stretching and thinning of the material on and around the offset, and enhancing the integrity of the structure. The offset structure can be formed using conventional manufacturing processes.