Method of making disk drives using a frame array with a plurality of disk drive base portions

An aspect of the invention can be regarded as a method of making disk drives. The method includes providing a frame array. The frame array includes a frame, a plurality of disk drive base portions, and a plurality of tie bars connected between the frame and the disk drive base portions. The method further includes attaching a respective disk drive component to each of the disk drive base portions. The method further includes removing the disk drive base portions from the frame by severing the tie bars.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to disk drives, and in particular to a method of making disk drives using a frame array with a plurality of disk drive base portions.

2. Description of the Prior Art

The typical hard disk drive includes a head disk assembly (HDA) and a printed circuit board assembly (PCBA) may be attached to a disk drive base of the HDA or incorporated with circuitry associated with a host device that the disk drive supports. The head disk assembly includes the disk drive base, a cover, at least one magnetic disk, a spindle motor for rotating the disk, and a head stack assembly (HSA).

The spindle motor includes a spindle motor hub that is rotatably attached to the disk drive base. The spindle motor hub has an outer hub flange that supports a lowermost one of the disks. Additional disks may be stacked and separated with annular disk spacers that are disposed about the spindle motor hub. The spindle motor typically includes a spindle motor base that may be integrated with the disk drive base. A shaft is coupled to the spindle motor base and the spindle motor hub surrounds the shaft. The spindle motor hub may be rotatably coupled to the shaft, and therefore the spindle motor base, typically via a pair of bearing sets. A stator is positioned about the shaft and is attached to the spindle motor base. A magnet element is attached to the hub flange. The stator includes windings that selectively conduct current to create a magnetic field that interacts with the various poles of the magnet element. Such interaction results in forces applied to the spindle motor hub that tend to rotate the spindle motor hub and the attached disks.

The head stack assembly includes the actuator assembly, at least one head gimbal assembly (HGA), and a flex circuit cable assembly that are attached to the actuator assembly. A conventional “rotary” or “swing-type” actuator assembly typically comprises an actuator body, a pivot bearing cartridge, one or more actuator arms that extend from one side of the actuator body, and a coil portion that extends from an opposite side of the actuator body. The actuator body includes a bore and the pivot bearing cartridge engaged within the bore for allowing the actuator body to rotate between limited positions. The coil portion includes a coil that is configured to interact with one or more permanent magnets to form a voice coil motor.

At least one head gimbal assembly is distally attached to each of the actuator arms. A head gimbal assembly includes an air bearing slider with a transducer head. The voice coil motor is configured to allow the actuator assembly to be controllably rotated or pivoted so as to move the sliders with the transducer heads relative to the disks for reading and writing operations with respect to the tracks contained on the rotating disks. The printed circuit board assembly is disposed in electrical communication with the coil via the flex circuit cable assembly for providing a control current to energize the coil to create an electromagnetic field that interacts with the permanent magnets to controllably position the actuator assembly.

A topic of concern is the desire to reduce the overall disk drive size. Such disk drives may have a variety of applications such as in hand held or portable electronic devices. The exterior size and shape of the disk drive is often referred to as a “form factor”. Fabrication of such disk drives having reduced form factors has proven challenging. In this regard, the handling and assembly of the various disk drive components is difficult due to their relatively small size. Application of traditional disk drive fabrication techniques has proven to be inefficient with respect to mass production of such reduced form factor disk drives. Accordingly, there is a need in the art for an improved method of making disk drives in comparison to the prior art.

SUMMARY OF THE INVENTION

An aspect of the invention can be regarded as a method of making disk drives. The method begins with providing a frame array. The frame array includes a frame, a plurality of disk drive base portions, and a plurality of tie bars connected between the frame and the disk drive base portions. A respective disk drive component is attached to each of the disk drive base portions. Finally, the disk drive base portions are removed from the frame by severing the tie bars.

According to various embodiments of the present invention, the frame array may be formed of metal and may be of a stamped nature. Prior to the attachment of the disk drive components, the method may further include the step of partially encapsulating each of the disk drive base portions with a hardenable material. This may be accomplished through a molding process with the hardenable material being a plastic. In an embodiment, selected ones of the tie bars may be electrical leads. The disk drive components may be electrical components and the method may include respectively electrically connecting the electrical components to the electrical leads. The method may further include respectively testing operation of the disk drive components. The disk drive components may be head stack assemblies or spindle motors for example. In another arrangement, the frame array may be formed of plastic. In addition, a lead frame may be provided which is overlaid with the frame array. The lead frame includes electrical leads and the disk drive components may be electrical components with such electrical components being respectively electrically attached to the electrical leads. The method may further include insert molding respective inserts with each of the disk drive base portions. The inserts may be voice coil motor components for example. Further, the frame includes recesses for indexing the frame array.

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. 1–12illustrate methods of making disk drives in accordance with the aspects of the present invention.

FIGS. 1–6depict an embodiment of a frame array10as shown through a series of fabrication process steps of a method of an aspect of the present invention, andFIG. 7is a flow8diagram of the method. In this respect, an aspect of the invention can be regarded as a method of making disk drives. The method begins with step100of providing a frame array10as shown inFIG. 1. The frame array10includes a frame12, a plurality of disk drive base portions14, and a plurality of tie bars16connected between the frame12and the disk drive base portions14. As shown inFIG. 5, the method includes a step110of attaching a respective disk drive component, such as a head stack assembly18or a spindle motor20, to each of the disk drive base portions14. Finally, according to step120, the disk drive base portions14are removed from the frame12by severing the tie bars16. It is contemplated that the present method may facilitate a substantial amount of a fabrication process of a disk drive at a single fabrication station. In this regard, inefficiencies associated with individual handing of separately formed disk drive base portions14may be mitigated. Moreover, the use of the frame array10may even eliminate the need to utilize certain fabrication stations and thereby eliminate transit times to such stations.

In further detail, according to the embodiment of the frame array10ofFIG. 1, the frame array10is provided.FIG. 2is an enlarged view of a portion of the frame array10. In this embodiment, a four by five array of disk drive base portions14is depicted. It is contemplated that other configurations that include additional or fewer number of disk drive base portions14may be practiced. The number and configuration of the disk drive base portions14may be influenced by automated tooling and/or human handing limitations.

In this embodiment, the frame array10may be formed of a variety of material such as a metal material or a plastic material. The frame12, the disk drive base portions14, and the tie bars16may all be commonly formed of the same plastic material. As such, construction of the frame array10may be through an injection molding process. Various surface contour features may be incorporated into the design of the disk drive base portions14to perform the required functions of a disk drive base as utilized in a disk drive. This may include surface contour features that perform structural support for any number of disk drive components.

The frame12may include recesses18for indexing the frame array10. As such, fabrication tooling may engage the frame array10at the recesses18. For example, fabrication tooling may include a tooling block that the frame array10sits upon and pins may extend upward through the recesses18. Such recesses18need not be formed as holes as shown, but may be any number of geometries such as notches formed about the periphery of the frame12.

Referring now toFIG. 3, there is depicted the frame array10ofFIG. 1as shown with a lead frame22.FIG. 4depicts the lead frame22overlaid upon the frame array10. The method may provide for overlaying the lead frame22upon the frame array10. The lead frame22may be formed of a metal material as shown, or formed of a flex circuit or rigid material for example. In this regard, the lead frame22may include various electrical leads, such as electrical leads24,26. As mentioned above, the method includes a step110of attaching a respective disk drive component to each of the disk drive base portions14. In this regard, the method may further include respectively electrically attaching the disk drive components, such as a head stack assembly19or a spindle motor20, to the electrical leads24,26as shown inFIG. 5.

Referring now toFIG. 6, there is depicted step120of removing the disk drive base portions14from the frame12by severing the tie bars16. In this regard, three of the disk drive base portions14are shown as removed. In addition to severing the tie bars16, the electrical leads24,26may be severed during this step as well. It is contemplated that the tie bars16as well as the electrical leads24,26may be particularly formed to have a geometry which includes a region of less material or indentations so as to be readily severable (i.e., the disk drive base portions14may in effect be of a “snap out” type of part with respect to the frame12).

There is depicted another embodiment of a frame array28as shown inFIGS. 8–12. As shown inFIG. 8, the frame array28may take the form of a strip. The frame array28includes a frame30and disk drive base portions32. Tie bars34are disposed between the frame30and the disk drive base portions32.FIG. 9is an enlarged view of a portion of the frame array28ofFIG. 8. In this embodiment, the frame array28is formed of a metal material. Further, the frame array28may be of a stamped nature. Such a strip configuration of a stamped metal14material is contemplated to lend itself to a relatively continuous mass production technique as the frame array28may be dispensed in a roll form and reel fed into a fabrication station.

Referring now toFIG. 10, there is depicted the frame array28ofFIG. 8after having undergone an encapsulation process. As shown, the disk drive base portions32may be encapsulated with a hardenable material such as plastic. This may be accomplished through a molding process. The method may further include insert molding respective inserts with each of the disk drive base portions32. For example, the inserts may be voice coil motor components36such as a magnet and back iron. The inserts may further include spindle motor stators38. In this regard, the inserts may be electrical components that are attached to the disk drive base portions32through the molding process. The frame array28may further include electrical leads40,42. In this regard, selective ones of the tie bars34may be the electrical leads40,42. Further, as such inserts may be electrical components, the method may include respectively electrically connecting such electrical components to the electrical leads40,42. Referring now toFIG. 11, there is depicted the encapsulated frame array28ofFIG. 10with additional disk drive components in the form of head stack assemblies44and spindle motors46attached to the disk drive base portions32. Finally as shown inFIG. 12, there is depicted the frame array28ofFIG. 11with a couple of the disk drive base portions32removed.

The method may further include respectively testing operation of the disk drive components. In this regard, prior to the removal step, the various disk drive components may be tested, such as the spindle motors, the voice coil motors, and the head stack assemblies. As such disk drive base portions32are still attached to the frame30, the various components may be tested at the same single fabrication station where such components are attached, thereby avoiding the need to utilize a separate testing station.