Abstract:
A method of manufacturing a disk drive for use with a host electronic unit (HEU). The HEU including a printed circuit board having a socket and HEU disk drive circuitry. The method includes providing a lead frame. The lead frame is a single component having material continuity rather than an assembly of subcomponents. The method includes forming a plurality of leads in the lead frame by removing material of the lead frame, and attaching the lead frame to a housing body. The housing body defines a housing periphery sized and configured to be engaged within the socket. The leads extend to the housing periphery. The method includes attaching a disk drive electrical component to the housing body, and electrically connecting the disk drive electrical component to at least one of leads. The disk drive circuitry is located on the HEU printed circuit board rather than within the housing periphery.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a divisional patent application of U.S. application Ser. No. 10/183,067, entitled DISK DRIVE HOUSING INCLUDING HOUSING BODY WITH LEADS EXTENDING TO HOUSING PERIPHERY, filed on Jun. 26, 2002, the entire contents of which are incorporated herein by reference. In addition, this application is related to U.S. application Ser. No. 10/183,069, entitled HOST ELECTRONIC UNIT WITH DISK DRIVE SOCKET FOR INTERNAL ENGAGEMENT WITH DISK DRIVE, filed on Jun. 26, 2002, now abandoned, the entire contents of which are incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The present invention relates generally to disk drives, and more particularly to a method of manufacturing a disk drive with a lead frame engaged within a host electronic unit socket. 
   DESCRIPTION OF THE PRIOR ART 
   The typical hard disk drive includes a disk drive base, and a head disk assembly (HDA) and a printed circuit board assembly (PCBA) attached to the disk drive base. The head disk assembly includes at least one magnetic disk, a spindle motor for rotating the disk, and a head stack assembly (HSA) that includes at least one transducer head, typically several, for reading and writing data to and from the disk. As discussed further below, the printed circuit board includes functional portions of which may be characterized as spindle motor drive circuitry, actuator drive circuitry, and read channel circuitry. 
   The head stack assembly includes an actuator assembly, at least one head gimbal assembly, and a flex circuit cable assembly. A conventional “rotary” or “swing-type” actuator assembly typically comprises an actuator body that rotates on a pivot assembly between limited positions, a coil portion that extends from one side of the actuator body to interact with one or more permanent magnets to form a voice coil motor, and one or more actuator arms which extend from an opposite side of the actuator body. The actuator assembly includes the actuator body which has a bore and a pivot bearing cartridge engaged within the bore. A head gimbal assembly includes at least one transducer head, sometimes two, which is distally attached to each of the actuator arms. 
   The flex circuit cable assembly includes a flex circuit cable which is attached to the actuator assembly and electrically connects the various electrical components onboard the head stack assembly with a relatively minimal impact upon its pivoting movement. The actuator drive circuitry is configured to generate servo control signals. The head stack assembly is controllably positioned in response to the generated servo control signals from the actuator drive circuitry. In so doing, the attached heads are moved relative to tracks disposed upon the disk. As such, the flex circuit cable houses electrical connections between actuator drive circuitry and the coil portion of the actuator assembly. Further, the read channel circuitry is configured to receive data signal from the heads. As such, the flex circuit cable further houses the electrical connections between the read channel circuitry and the heads. 
   The spindle motor includes a hub that is rotatably attached to the disk drive base. The hub has an outer flange that supports one of the disks. Additional disks may be stacked and separated with spacers. The spindle motor further includes an annular magnet and a spindle motor stator. Where space efficiency is of vital concern, the magnet is typically attached about the lowermost portion of the hub below the flange. The magnet consists of a predetermined number of N and S poles that are disposed alternately circumferentially about the magnet. The spindle motor stator includes an outer rim that is attached to the disk drive base and a plurality of internally facing stator teeth. The stator teeth are equally spaced and extend from the stator rim. The spindle motor stator is sized to fit about the hub and in particular the magnet. Each stator tooth includes windings which selectively conduct current to create a magnetic field that interacts with the various poles of the magnet. Such interaction results in forces applied to the hub which tend to rotate the hub. The spindle motor drive circuitry is configured to generate electrical signals to the stator, and in particular the windings thereof, for controlling the movement of the spindle motor. 
   Such disk drives may have a variety of applications in any number of host electronic devices, such as hand held or portable devices such as computer laptops, cellular telephones, personal digital assistants (PDA), digital cameras, etc. A topic of concern is the desire to reduce the overall disk drive size and well as that of the associated host electronic device. In this regard, a disk drive may be of an internal nature or externally connectable such as in an external port or other interface of the associated host electronic unit. In this regard, one particular area of focus is the mechanical and electrical connections between the various electrical components of the disk drive and the associated host electronic unit. Accordingly, there is a need in the art for an improved arrangement for the electrical connections between various disk drive electrical components and the associated host electronic unit in comparison to the prior art. 
   SUMMARY 
   An aspect of the invention can be regarded as a method of manufacturing a disk drive for use with a host electronic unit (HEU). The HEU includes a printed circuit board having a disk drive socket and HEU disk drive circuitry in electrical communication with the disk drive socket. The method includes providing a lead frame. The lead frame is a single component having material continuity rather than an assembly of subcomponents. The method further includes forming a plurality of leads in the lead frame by removing material of the lead frame. The method further includes attaching the lead frame to a housing body. The housing body defines a housing periphery sized and configured to be engaged within the disk drive socket. The plurality of leads extend to the housing periphery for electrically communicating with the disk drive circuitry with the housing body being internally engaged within the disk drive socket. The method further includes attaching a disk drive electrical component to the housing body. The method further includes electrically connecting the disk drive electrical component to at least one of the plurality of leads, the leads allowing the HEU disk drive circuitry to control the disk drive electrical component. The disk drive circuitry is located on the HEU printed circuit board rather than within the housing periphery. 
   According to various embodiments, the lead frame may be formed from a carrier strip. The forming of the plurality of leads in the lead frame may include trimming the lead frame. The trimming of the lead frame may occur prior to or after attaching of the lead frame to a housing body. The forming of the plurality of leads in the lead frame may include stamping the lead frame. The housing body and the lead frame may be separately formed. The housing body may be formed from a carrier strip. The housing body may be formed by a stamping process. The attaching of the lead frame to a housing body may include stamping the lead frame and the housing body. The disk drive component may be a spindle motor and/or head stack assembly, for examples. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exploded perspective view of a disk drive with a disk drive housing including housing body (in a stamped form embodiment) and a lead frame and disk drive components, as shown during fabrication before completion; 
       FIG. 2  is a perspective view of the disk drive of  FIG. 1  as assembled; 
       FIG. 3  is a perspective view of the disk drive of  FIG. 2  with portions of the housing body and lead frame trimmed for forming leads and for sizing; 
       FIG. 4  is a perspective view of the disk drive of  FIG. 3  with the leads formed about the housing body and shown with a cover; 
       FIG. 5  is a symbolic diagram of the disk drive of  FIG. 4  as received by a socket mounted upon a printed circuit board of a host electronic unit; 
       FIG. 6  is an exploded perspective view of a disk drive with a disk drive housing including a housing body (in overmolded form embodiment) and a lead frame and disk drive components, as shown during fabrication before completion; 
       FIG. 7  is a perspective view of the disk drive of  FIG. 6  as assembled; 
       FIG. 8  is a perspective view of the disk drive of  FIG. 7  with portions of the housing body and lead frame trimmed for forming leads and for final sizing; 
       FIG. 9  is a perspective view of the disk drive of  FIG. 8  with the leads formed about the housing body and shown with a cover; 
       FIG. 10  is a cross sectional view of a portion of the disk drive of  FIG. 9  as seen along axis  10 - 10  and in particular of a lead disposed thereat in a J-lead configuration; 
       FIG. 11  is a perspective view of the disk drive of  FIG. 9  with the cover attached as shown as being received by a socket mounted upon a printed circuit board of a host electronic unit; 
       FIG. 12  is a cross sectional view of a portion of a disk drive similar to that of  FIG. 10 , however, with a lead in a compression contact configuration; 
       FIG. 13  is a perspective view of a disk drive similar to that of  FIG. 9 , however, with leads in a surface mount configuration as shown with a portion of a printed circuit board of a host electronic unit; and 
       FIG. 14  is a cross sectional view of a portion of the disk drive of  FIG. 13  as seen along axis  14 - 14  and in particular of a lead disposed thereat in a surface mount configuration. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same,  FIGS. 1-14  illustrate disk drives during various phases of manufacture in accordance with the aspects of the present invention. 
   Referring now to  FIG. 1 , there is depicted an exploded perspective view of a disk drive  10  as shown during fabrication before completion. The disk drive  10  includes a disk drive housing  12 . The disk drive housing  12  includes a housing body  14  and a lead frame  16 . In the embodiment shown, the housing body  14  is formed of a stamped material, such as a stamped metal material. The lead frame  16  may be likewise formed of a stamped material. An electrically conductive material such as a thin metal may be utilized to form the lead frame  16 . The disk drive  10  further includes a head stack assembly  18  and at least one magnetic disk  20  supported by a spindle motor hub  22 . A spindle motor stator  24  is configured to interact with the hub  22  to form a spindle motor  25  for rotating the hub  22 . It is contemplated that the stamped nature of the housing body  14  and the lead frame  16  readily facilitates formation of geometric features and details to accommodate the attachment and positioning of the various disk drive components such as the head stack assembly  18 , the magnetic disk  20 , the spindle motor hub  22 , and the spindle motor stator  24 . Furthermore, the lead frame  16  is formed to include elongate gaps  26 . The gaps  26  define a plurality of leads  28  formed in the lead frame  16  as shown and discussed in detail in reference to  FIGS. 3 and 4  below. 
   Referring now additionally to  FIG. 2 , there is depicted the disk drive  10  of  FIG. 1  as assembled. In this regard, substantial structural integrity of the disk drive housing  12  is associated with the housing body  14 . The housing body  14  is attached to the lead frame  16  via any number of attachment processes well known in the art such as a stamping process or adhesive bonding for example. In practice, though not shown, an insulative layer or coating is disposed between the housing body  14  and the lead frame  16  to insulate the lead frame  16  from electrically shorting through conductive contact with the housing body  14  in this metal material embodiment. 
   Referring now additionally to  FIG. 3 , there is depicted a perspective view of the disk drive  10  of  FIG. 2  with portions of the housing body  14  and the lead frame  16  having been trimmed off or otherwise removed during the fabrication process. It is contemplated that the trimming process may occur before or after the attachment of the housing body  14  to the lead frame  16 . At this stage, the housing body  14  is formed to define a housing periphery  30 . As can be seen, the trimming of the lead frame  16  defines the leads  28 . In this regard, the selective layout of the elongate gaps  26  and trimming of the lead frame  16  crosswise to the gaps  26  results the formation of the leads  28  having distal ends  32  disposed generally outwardly facing of the lead frame  16 . Moreover, the leads  28  are generally arrayed to extend to the housing periphery  30 . 
   Referring now additionally to  FIG. 4 , there is depicted a perspective view of the disk drive  10  of  FIG. 3 . The distal ends  32  of the plurality of leads  28  are formed about the housing body  14  at the housing periphery  30 . This may be accomplished via a bending process for example. In the embodiment shown, the leads  28  are formed to be of a J-lead or butt lead configuration. A cover  34  is shown in exploded view above the housing body  14 . The cover  34  further defines the disk drive housing  12  and is attached to the housing body  14  for cooperatively enclosing various other disk drive components therein. 
   Referring now additionally to  FIG. 5 , there is depicted a symbolic diagram of the disk drive  10  of  FIG. 4  as shown in relation to a host electronic unit  36  that utilizes the disk drive  10 . The host electronic unit  36  includes a printed circuit board  38 . A disk drive socket  40  is mounted upon the printed circuit board  38 . The disk drive  10  communicates with the disk drive socket  40  via the distal ends  32 . Disk drive circuitry  44  is disposed upon the printed circuit board  38  in electrical communication with the disk drive socket  40 . Electrical interconnections  42  are representatively shown between the disk drive socket  40  and the disk drive circuitry  44 . 
   According to an aspect of the invention there is provided the disk drive housing  12  for use with the host electronic unit  36 . The host electronic unit  36  includes the printed circuit board  38  with the disk drive socket  40  and the disk drive circuitry  44  in electrical communication with the disk drive socket  40 . The disk drive housing  12  includes the housing body  14  defining the housing periphery  30 . The housing periphery  30  is sized and configured to be internally engaged within the disk drive socket  40 . The disk drive housing  12  further includes the lead frame  16  attached to the housing body  14 . The lead frame  16  includes the plurality of leads  28  extending to the housing periphery  30  for electrically communicating with the disk drive circuitry  44  with the housing body  14  being internally engaged within the disk drive socket  40 . It is contemplated that the peripheral nature of the leads  28  facilitates a generally low height profile of the overall disk drive  10  and that of the associated host electronic unit  36 . Moreover, advantages may be realized in connection with fabrication efficiencies through the use of carrier strip technology for production of the housing body  14  and the lead frame  16 . As such, this design may tend to lend itself to mass production techniques. Further, in this embodiment, the stamped nature of the housing body  14  and the lead frame  16  facilitates ease of design changes with respect to modification of various lead configurations. 
   It is contemplated that the disk drive circuitry  44  may include spindle motor drive circuitry for controlling the spindle motor  25 . In this regard, the spindle motor drive circuitry generates electrical signals that are passed to windings of the spindle motor stator  24  via the leads  28  for controlling the rotational movement of the hub  22 . The disk drive circuitry  44  may include actuator drive circuitry for controlling movement of the head stack assembly  18  relative to the disk  20 . Further, the disk drive circuitry  44  may include read channel circuitry for receiving electrical signals from the head stack assembly  18  representative of data disposed upon the disk  20 . 
   As used herein, the housing body  14  being internally engaged within the disk drive socket  40  refers to at least a portion of the disk drive socket  40  being physically disposed about the housing periphery  30  and configured to electrically communicate with the leads  28  disposed at the housing periphery  30 . 
   According to another aspect of the present invention there is provided the disk drive  10  for use with the host electronic unit  36  including the printed circuit board  38  with the disk drive socket  40  and disk drive circuitry  44  in electrical communication with the disk drive socket  40 . The disk drive  10  includes the disk drive housing  12  as described above. The disk drive  10  further includes a disk drive electrical component, such as the spindle motor  25  or the head stack assembly  18 , attached to the disk drive housing  12  in electrical communication with at least one of the plurality of leads  28 . 
   As shown in  FIGS. 6-10 , there is depicted a disk drive  46  according to another embodiment. Referring to  FIG. 6  there is an exploded perspective view of the disk drive  46  as shown during fabrication before completion. The disk drive  46  is similar in construction to the disk drive  10  as described above except for those differences noted below. The disk drive  46  includes a disk drive housing  48 . The disk drive housing  48  includes a housing body  50  and a lead frame  52 . In this embodiment, the housing body  50  is formed of a molded material. For example, the housing body  50  may be formed of a molded plastic material. The lead frame  52  may be constructed similar to that of lead frame  16  described above. As the housing body  50  is of a molded nature, it is integrally formed about the lead frame  52 . In this regard, it is understood that the housing body  50  is shown separately from the lead frame  52  for ease of illustration. The disk drive housing  48  may further include a frame  54  for attachment to the lead frame  52  opposite the housing body  50 . The frame  54  may be integrally formed with the housing body  50  during the molding process.  FIG. 7  depicts the disk drive  46  of  FIG. 6  with the housing body  50  and the frame  54  as integrally formed about the lead frame  52 . 
   Referring now additionally to  FIG. 8  there is depicted a perspective view of the disk drive  46  of  FIG. 7  with portions of the housing body  50  and the lead frame  52  having been trimmed off or otherwise removed during the fabrication process. At this stage, the housing body  50  is formed to define a housing periphery  56 . As can be seen, the trimming of the lead frame  52  defines a plurality of leads  58 . The leads  58  have distal ends  60  disposed generally outwardly facing of the lead frame  52 . Moreover, the leads  58  are generally arrayed to extend to the housing periphery  56 . 
   Referring now additionally to  FIG. 9 , there is depicted a perspective view of the disk drive  46  of  FIG. 8 . The distal ends  60  of the plurality of leads  58  are formed about the housing body  50  at the housing periphery  56 . In the embodiment shown, the leads  58  are formed to be of a J-lead or butt lead configuration. A cover  62  is shown in exploded view above the housing body  50 . The cover  62  further defines the disk drive housing  48  and is attached to the housing body  50  for cooperatively enclosing various other disk drive components therein. 
   Referring now additionally to  FIG. 10 , there depicted is a cross sectional view of a portion of the disk drive  46  of  FIG. 9  as seen along axis  10 - 10 . As can be seen the lead  58  is disposed in a J-lead or butt lead configuration with the distal end  60  externally disposed at the housing periphery  56 . 
   Referring now additionally to  FIG. 11 , there is depicted a perspective view of the disk drive  46  of  FIG. 9  with the cover  62  attached. The disk drive  46  is shown as being received by a disk drive socket  64  mounted upon a printed circuit board  66  of a host electronic unit  68  similar in construction as the host electronic unit  36  described above. 
   Referring now to  FIG. 12 , there is depicted a cross sectional view of a portion of a disk drive similar to the disk drive  46  of  FIG. 10 , however, with the lead  58  substituted with a lead  70 . Lead  70  is disposed in a compression contact configuration according to another embodiment of the present invention. In this regard, lead  70  includes a distal end  72  that is deformed radially outward from the housing body  50 . Upon the housing body  50  being received in a disk drive socket  64 , it is contemplated that the distal end  72  is deflected towards the housing body  50  and exerts a compressive force in response for facilitating electrical contact and mechanical engagement. 
   As shown in  FIGS. 13 and 14 , there is depicted a disk drive  74  according to another aspect of the present invention.  FIG. 13  is a perspective view of the disk drive  74  similar to disk drive  46  of  FIG. 9 . It is contemplated that the disk drive  74  includes a lead frame  76  and a housing body  78  respectively similar to the lead frame  52  and housing body  50 , however, with a plurality of leads  80  substituted for leads  58 . The leads  80  are disposed in a surface mount configuration. In this regard, the disk drive  74  is depicted with a portion of a printed circuit board  82  of a host electronic unit  84 . The leads  80  include distal ends  86  thereof which may be mounted upon the printed circuit board  82  for electrical connection with disk drive circuitry  88  disposed upon the printed circuit board  82 .  FIG. 14  is a cross sectional view of a portion of the disk drive  74  of  FIG. 13  as seen along axis  14 - 14  and in particular of a lead  80  disposed thereat in the surface mount configuration. The distal end  86  is shown as radially facing outward of a housing periphery  90  of the housing body  78 . It is contemplated that other orientations may be utilized such as the distal end  86  being folded under the housing body  78 . 
   As such, according to another embodiment, there is provided a disk drive housing  92  for use with the host electronic unit  84  including the printed circuit board  82  and disk drive circuitry  88 . The disk drive housing  92  includes the housing body  78  defining the housing periphery  90 . The disk drive housing  92  further includes a lead frame  76  attached to the housing body  78 . The lead frame  76  includes the plurality of leads  80  extending to the housing periphery  90 . Each of the leads  80  includes a distal end  86  for electrically communicating with the disk drive circuitry  88  with the distal end  86  mounted upon the printed circuit board  82 . According to another embodiment, there is provided the disk drive  74  for use with the host electronic unit  84  including the printed circuit board  82  and disk drive circuitry  88 . The disk drive  74  includes a disk drive housing  92  as described above.