Method for manufacturing a hard disk drive arm

A system and method are disclosed for improving suspension-to-slider attachment in a hard disk drive. A slider having a number of bond pads on its leading edge and a number of bond pads on its trailing edge is to be coupled to a suspension flexure having a number of leading bond pads and a number of trailing bond pads. The slider is to be coupled to the suspension flexure at the leading bond pads and the trailing bond pads by a method such as gold ball, solder ball, or solder bump bonding.

BACKGROUND INFORMATION

The present invention relates to hard disk drives. More specifically, the invention relates to a system and method for improving slider attachment.

FIG. 1graphically illustrates a typical head-gimbal assembly (HGA) of a hard disk drive with disk media as used in the art. Hard disk drive storage devices typically include a rotating disk9containing concentric data tracks in which data is read from and written to by a slider1(containing a transducer head, not shown). The slider1, which ‘flies’ close to the surface of the rotating disk9, is typically attached to a load beam8by a suspension flexure6. The slider (head)1is mounted to the flexure6by epoxy bonding5(SeeFIG. 2). The suspension flexure6allows the slider1to pitch and roll with respect to the disk9while the load beam8provides loading force (by spring action) towards the disk9during flight (countering the slider's lift).

Typically, the load beam8provides resilient spring action, which biases the slider towards the surface of the disk9, while the flexure6provides pitch and roll flexibility for the slider as the slider rides on a cushion of air between the air bearing surface (slider1surface) and the rotating disk9.

FIG. 2provides a perspective view of a typical slider-suspension flexure assembly as used in the art. In a typical slider-suspension assembly, the slider1is epoxy-bonded to the suspension flexure6, and the head's1transducer leads are electrically coupled to leads formed on the suspension flexure6. The electrical connections3between the slider pads2and the flexure trace pads4are typically created by gold ball, solder ball, or solder bump bonding. The fabrication of such a slider suspension assembly is time consuming and costly.

FIG. 3illustrates the attachment of a slider to a suspension flexure as typically performed in the art. Typically, a predetermined amount of epoxy5is placed on the tongue portion of the suspension flexure6where the slider1is to be located. The slider1is subsequently positioned onto the suspension flexure6with an alignment device, such as a vacuum tube21. After the epoxy hardens to a degree, e.g. by ultra-violet (UV) light, electrical connections (such as by gold/solder ball or solder bump bonding) are made between the pads2of the slider head transducer and the suspension pads4. The epoxy5is then further hardened by a method such as oven baking.

FIG. 4provides a graphical illustration of a slider mounted upon a suspension flexure as is typical in the art. There are several disadvantages associated with the typical method of slider-suspension attachment. One problem involves the residual welding stress caused by the hardened epoxy5and soldered bump/gold ball3bonding. Typically in the art, it is difficult to apply the epoxy perfectly evenly, and as a result, the thick portion of the applied epoxy and the residual internal stress of the solder/gold ball bonding, cause changes in the slider1attitude angle and force the slider1to become askew with respect to the suspension flexure6. (See alsoFIG. 5).

FIG. 5illustrates a slider mounted askew with respect to a suspension flexure as is common in the art. The pitch22attitude angle of the slider1may seriously degrade while the epoxy5is curing.

It is therefore desirable to have a simplified system and method for manufacturing a hard disk drive slider-suspension assembly that avoids the above-mentioned problems, as well as having additional benefits.

DETAILED DESCRIPTION

FIG. 6illustrates slider-suspension attachment according to an embodiment of the present invention. In one embodiment, the slider1is mounted to the suspension flexure6by a simplified process. In this embodiment, improved Pitch Static Attitude (“RSA”) and Roll Static Attitude (“RSA”) are achieved by bonding (such as by gold ball, solder ball, or solder bump) the slider1to the suspension flexure6at the leading edge and the trailing edge. In addition to a more stable bond (reduced likelihood of shifting out of alignment), the process is simplified and less expensive as compared to the prior art. Because epoxy is not utilized, the tooling necessary is reduced.

In one embodiment of the present invention, transducer electrical bonding pads2of the slider1are coupled by a method such as gold ball, solder ball, or solder bump bonding to electrical bonding pads4of the suspension flexure6. In addition, in this embodiment grounding bonding pads11of the slider1are coupled by a method such as gold ball, solder ball, or solder bump bonding to corresponding grounding bonding pads9of the suspension flexure6. By utilizing bonds3at the leading edge and the trailing edge of the slider1, the need for epoxy is eliminated. Further, in this embodiment the utilization of the grounding pad11,9coupling reduces the likelihood of damage to the slider1transducer head caused by Electro-Static Discharge (ESD).

In one embodiment, a placement device21is utilized to position (e.g., by vacuum tube) the slider1upon the suspension flexure6for the pads2,4,9,11to be bonded3by a method such as gold ball, solder ball, or solder bump bonding. Once the bonding3has cooled and hardened, in this embodiment the placement device21releases the slider1, and the slider1remains attached to the suspension flexure6in the appropriate orientation.

FIG. 7illustrates a suspension flexure with circuitry according to an embodiment of the present invention. In one embodiment, four transducer electrical pads4and two grounding pads9are utilized. In one embodiment, two slots12are utilized for relieving any residual stress created in the flexure from slider assembly.

FIG. 8provides a perspective view of a slider attached to a suspension flexure according to an embodiment of the present invention.

FIG. 9provides a perspective view of a slider attached to a suspension flexure according to an alternative embodiment of the present invention. In this alternative embodiment of the present invention, the slider1is bonded to the suspension flexure6at the trailing edge, such as by gold ball, solder ball, or solder bump bonding, without bonding pads (i.e, for physical coupling only, not for electrical grounding). In another alternative embodiment, the slider is bonded to the suspension flexure at the leading edge without bonding pads (not shown).

Although several embodiments are specifically illustrated and described herein, it will be appreciated that modifications and variations of the present invention are covered by the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention.