Suspension Flexure Forming for Gimbal Clearance Stability

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Solution Overview

Problem

The challenge in hard disk drives is the instability of gimbal resonance modes due to mechanical interference between the flexure and load beam, particularly at the weld attachment points, which occurs due to variations in mechanical tolerances and media load height differences, leading to unstable suspension resonance frequencies.

Innovation Solution

A clearance is formed between the pivoting gimbal flexure and the load beam by mechanical flexure forming or localized permanent deformation via laser radiation along the centerline of the flexure part, ensuring the gimbal portion is formed away from the load beam to prevent interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical tolerances and media load height variations occur, then the flexure and load beam may contact each other, but this contact causes instability in gimbal resonance modes

Engineering Contradiction:

Improvestability of gimbal resonance modesVSAvoidmechanical interference between flexure and load beam

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by forming a clearance gap between the flexure and load beam before assembly through mechanical flexure forming or localized permanent deformation. This pre-established clearance prevents contact and mechanical interference during operation, eliminating the source of resonance mode instability before it can occur.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the potential harm of mechanical contact into a benefit by intentionally creating a controlled clearance. The clearance that would normally be considered wasted space is instead used as a protective feature that prevents harmful contact between components, stabilizing the resonance modes while accommodating manufacturing tolerances and load variations.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If the flexure is formed to create clearance from the load beam, then mechanical interference is prevented, but additional manufacturing steps are required

Engineering Contradiction:

Improvestability of suspension resonance modesVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts the interference problem by separating the flexure from the load beam through localized permanent deformation or mechanical forming. By taking out the potential contact zones and creating clearance, the harmful mechanical interference is eliminated while maintaining the functional integrity of both components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies local quality by performing localized permanent deformation or mechanical forming at specific regions of the flexure near the load beam interface. This localized treatment creates clearance only where needed to prevent interference, while leaving the rest of the flexure structure unchanged and maintaining its original manufacturing simplicity.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If clearance is formed between flexure and load beam, then gimbal resonance modes are stabilized, but the flexure requires additional forming operations

Engineering Contradiction:

Improveclearance formation precisionVSAvoidflexure forming process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by modifying the physical state of the flexure through localized permanent deformation or mechanical forming. These parameter changes alter the geometry of the flexure in the specific region near the load beam, creating a controlled clearance gap that ensures stable resonance modes while accommodating manufacturing tolerances.

Inventive Principle:

Principle #35Parameter changes

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

This approach stabilizes suspension resonance modes by preventing mechanical interference, ensuring stable operation across varying load z-heights and enhancing dynamic performance.

Implementation Method 1

localized permanent deformation via laser radiation along the centerline of the flexure part

Methodology Applied

Scientific EffectLaser radiation: Laser

Implementation Method 2

localized permanent deformation via laser radiation

Methodology Applied

Scientific EffectThermal deformation: Heating

Data Source

PatentUS12592250B2Suspension flexure forming for gimbaling clearance

Publication Date: 2026.03.31 WESTERN DIGITAL TECHNOLOGIES INC

AI summary

A suspension assembly for a hard disk drive includes a load beam coupled with a corresponding flexure via a centerline weld at a distal portion of the flexure, where the flexure further includes a gimbal portion at least in part formed away from the load beam in proximity to the centerline weld. The gimbal portion may be formed away from the load beam by way of mechanical forming prior to welding to the load beam and/or at least lateral portions may be formed away from the load beam by way of laser irradiation to the flexure subsequent to welding to the load beam. In either case, clearance between the pivoting gimbal flexure and the corresponding load beam around the vicinity of the centerline weld attachment point is enabled, to provide freedom from interference between the parts and stable resonance modes throughout the media load z-height variations.