Parabolic Lapping Carrier Bridge for Bar End Actuation
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Solution Overview
Problem
Existing lapping carrier systems for data storage device components lack precision, leading to high fabrication scrap and variations in data access performance due to inconsistent actuation force at the ends of bars during the lapping process.
Innovation Solution
A lapping carrier system with a bridge configuration that varies joint distances in a parabolic shape and longer bridge length, combined with customized end joints and fingers, to enhance actuation force and control at the ends of bars, improving precision and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional lapping carrier system is used with uniform joint spacing, then the structure is simple and easy to manufacture, but the actuation force at the ends of bars is insufficient and inconsistent
Solution Approach 1:
The patent applies local quality by varying the joint spacing along the bridge length. Joints are positioned closer together at the ends of the bridge where actuation force is needed, and farther apart at the center. This non-uniform distribution provides enhanced actuation force and control at the bar ends while maintaining structural integrity throughout the carrier insert.
Solution Approach 2:
The carrier insert is designed with flexible fingers that can deflect and adapt to the bar geometry. The dynamic response of the fingers, combined with the optimized joint spacing, allows the system to provide consistent actuation force across bars of varying lengths and positions, improving manufacturing precision.
2Manufacturing precision
If the bridge length is increased to improve bar end control, then the actuation force at bar ends improves, but the carrier insert becomes more flexible and less stable
Solution Approach 1:
The bridge is designed with non-uniform joint spacing where joints are concentrated at the ends and spaced farther apart at the center. This local variation provides the necessary flexibility at the bar ends for precise control while maintaining stability in the central region through sparser joint placement.
Solution Approach 2:
The bridge is divided into multiple segments between joints, with varying numbers of segments along its length. This segmentation allows different portions of the bridge to have different stiffness characteristics, enabling both flexibility at the ends for precision control and stability in the center for overall carrier integrity.
3Productivity
If conventional carrier inserts are used, then the manufacturing process is simple, but fabrication scrap is high due to precision issues
Solution Approach 1:
The optimized joint spacing distribution concentrates joints at critical locations (bar ends) where precision is most important for lapping. This local quality improvement reduces fabrication scrap by ensuring high precision where it matters most, while maintaining simpler manufacturing than would be required for uniform high-precision structures throughout.
Data Source
AI summary
Embodiments of the present disclosure demonstrate a lapping carrier system for a bar to be lapped. The lapping carrier system may be configured with a single piece insert whose bridge is separated from a plurality of joints of the carrier insert by a varying distance. The varying distance can be greater at a medial portion of the bridge than at an end portion of the bridge to collectively form a parabolic shape. In some embodiments, a lapping insert can include a bridge with its length longer than the bar. In some embodiments in a lapping insert, the centerline between the end joint edge and the end finger edge extends beyond the edge of bar.