Tri-Stage Actuator Attachment on Flexure via Welding

Solution Overview

Problem

There is a need for improved suspensions in hard-disk drives with enhanced performance capabilities, particularly in terms of manufacturing efficiency and reduced contamination risks within the clean room environment.

Innovation Solution

A method of manufacturing a tri-stage assembly by directly attaching microactuators to a trace gimbal during the PZT on flexure process, which includes welding a baseplate, load beam, and trace gimbal together, minimizing the use of adhesives and allowing for efficient attachment of damping materials, thereby reducing manufacturing complexity and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional adhesive-based methods are used to attach actuators to the suspension, then ease of manufacture is improved, but contamination risk and manufacturing cost increase

Engineering Contradiction:

Improveease of manufactureVSAvoidcontamination risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the adhesive layer from the actuator attachment process. Instead of using adhesives to bond the PZT actuators to the trace gimbal, the actuators are directly attached through welding or mechanical attachment methods, eliminating the source of contamination and adhesive-related manufacturing complexities.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesives) with a mechanical/thermal bonding mechanism (welding or direct mechanical attachment). This substitution eliminates the need for adhesive application, curing, and cleanup processes, thereby reducing contamination risk and manufacturing cost while improving reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If multiple separate attachment processes are used for actuators, then manufacturing precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvemanufacturing precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the attachment of multiple actuators (mPZT and uPZT) to the trace gimbal into a single integrated process step. Both actuators are attached simultaneously during the same manufacturing operation, reducing the number of separate processes from two or more to one, thereby simplifying device complexity and reducing manufacturing cost while maintaining precision through proper fixture design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a universal attachment process that can handle multiple different actuator types (mPZT and uPZT) and attach them to different locations on the trace gimbal simultaneously. This multi-functional attachment process eliminates the need for separate specialized processes for each actuator, reducing overall process complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If adhesive-based attachment methods are used, then ease of manufacture is improved, but manufacturing cost and contamination risk increase

Engineering Contradiction:

Improveease of manufactureVSAvoidcontamination risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the adhesive layer from the actuator attachment process. Instead of using adhesives to bond the PZT actuators to the trace gimbal, the actuators are directly attached through welding or mechanical attachment methods, eliminating the source of contamination and adhesive-related manufacturing complexities.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesives) with a mechanical/thermal bonding mechanism (welding or direct mechanical attachment). This substitution eliminates the need for adhesive application, curing, and cleanup processes, thereby reducing contamination risk and manufacturing cost while improving reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables precise head positioning with reduced contamination risks and manufacturing costs, improving the reliability and performance of hard-disk drive suspensions by minimizing adhesive use and integrating passive damping for vibration suppression.

Implementation Method 1

welding a baseplate, load beam and trace gimbal together

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

first electrically conductive adhesive contacting at least a portion of the first electrode at the proximal end to connect the first electrode to a trace gimbal

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

first non-conductive adhesive contacting at least a portion of the second electrode and the microactuator at the proximal end to secure the microactuator to a trace gimbal

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11348608B2Tri-stage design for actuator attachment on flexure

Publication Date: 2022.05.31 MAGNECOMP CORP

AI summary

A method of manufacturing a tri-stage assembly is described herein. The method includes attaching a first microactuator and a second microactuator to a trace gimbal to a flexure during a PZT on flexure process (POF). The first microactuator is located at a distal end of the flexure and the second microactuator located at a proximal end of the flexure. The method also includes welding the trace gimbal to a baseplate, and a load beam to secure the trace gimbal including the first microactuator and the second microactuator.