Piezoelectric Element Connectivity Inspection via Adhesive Imaging
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Solution Overview
Problem
The existing methods for manufacturing magnetic head suspensions with piezoelectric elements fail to effectively confirm stable electrical connectivity between the first electrode of the piezoelectric element and its connection region due to potential over-spread of the conductive adhesive, leading to unreliable connections.
Innovation Solution
An inspection method and manufacturing process that involves calculating the amounts of insulation and conductive adhesives using imaging devices, determining electrical connectivity based on adhesive area or volume differences, ensuring precise application of the conductive adhesive to establish reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first electrode conductive adhesive is applied to electrically connect the first electrode and the support portion, then electrical connectivity is established, but it is impossible to confirm whether stable electrical connection is achieved due to potential over-spread of the adhesive
Solution Approach 1:
The patent applies imaging capture before the conductive adhesive dries to record the exact application area and shape. This preliminary action allows subsequent comparison between the actual adhesive application and the predetermined appropriate application area, enabling verification of proper electrical connection before the adhesive sets and becomes impossible to inspect.
Solution Approach 2:
The patent creates an image copy (photograph) of the adhesive application area and compares it with the predetermined appropriate application area. This copying approach allows for objective verification of whether the conductive adhesive was applied correctly without physically disturbing the connection, thus confirming electrical connectivity reliability.
2Reliability
If the conductive adhesive is applied generously to ensure coverage, then electrical connection is more likely to be established, but the adhesive may spread beyond the predetermined region reducing contact area effectiveness
Solution Approach 1:
The patent implements a feedback mechanism where the actual adhesive application area (captured by imaging) is compared with the predetermined appropriate application area. Based on this comparison, it can be determined whether the adhesive application was appropriate, providing feedback for quality control and enabling correction or rework if the application deviates from specifications.
Solution Approach 2:
The patent utilizes UV irradiation to cause fluorescent substances in the adhesive to emit visible light, creating a color change effect. This allows for clear visualization and imaging of the adhesive boundaries, enabling precise measurement and comparison of the application area against the predetermined appropriate area, thus improving manufacturing precision.
3Reliability
If inspection methods are added to verify electrical connectivity, then manufacturing yield and reliability can be improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent replaces complex electrical connectivity inspection methods with a simplified imaging-based approach. Instead of using sophisticated electrical testing equipment to verify connections, the system uses photographs and image processing to confirm that adhesive was applied to the correct area, which indirectly verifies electrical connectivity. This substitution significantly reduces inspection process complexity while maintaining reliability.
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 method effectively inspects and ensures stable electrical connectivity between the first electrode and its connection region, improving manufacturing yield and reliability of the magnetic head suspension.
Implementation Method 1
an insulation calculation step of calculating, after fixing the piezoelectric element to the predetermined mounting position by the first insulation adhesive, an amount of the first insulation adhesive existing on an inspection area
Implementation Method 2
a magnetic head suspension including the piezoelectric element that finely moves a gimbal region in a seek direction parallel to a disk surface
Data Source
AI summary
The present invention includes an insulation calculation step of calculating, after fixing a piezoelectric element to a predetermined mounting position by a first insulation adhesive, an amount of the first insulation adhesive existing on an inspection area set so as to include a part or all of at least one of a first electrode terminal region and a first electrode connection region, a conduction calculation step of calculating, after electrically connecting the first electrode terminal region to the first electrode connection region by an conductive adhesive, an amount of the conductive adhesive existing on the inspection area and a determination step of determining electrical connectivity between the first electrode and the first electrode connection region on the basis of a difference between calculation values in the conduction calculation step and the insulation calculation step.