Abstract:
Flexure/transducer structure employable in an electromagnetic information storage and retrieval system wherein mechanical load-bearing responsibilities and electrical-current-carrying responsibilities are merged into and shared by common structure. The invention subject matter is useable in systems characterized by contact operation, as well as by quasi-contact and noncontact operations, in relation to the recording surface in an information recording medium.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This is a continuation application of U.S. patent application Ser. No. 08/338,394 which was filed on Nov. 14, 1994, which is a continuation-in-part of U.S. patent application Ser. No. 08/191,967 (now abandoned) which was filed on Feb. 4, 1994, which was a continuation-in-part of U.S. patent application Ser. No. 07/919,302 (now abandoned) which was filed on Jul. 23, 1992, which was a continuation-in-part of U.S. Pat. No. 5,174,012 which was filed on Dec. 12, 1991 and issued on Dec. 29, 1992, which was a continuation of U.S. Pat. No. 5,073,242 which was filed on Jul. 24, 1991 and issued on Dec. 17, 1991, which was a continuation of U.S. Pat. No. 5,041,932 which was filed on Nov. 27, 1989 and issued on Aug. 20, 1991. This is also a continuation-in-part of U.S. patent application Ser. No. 07/990,005 (now abandoned) filed Dec. 10, 1992 which is a continuation of U.S. patent application Ser. No. 07/746,916 (now abandoned) filed on Aug. 19, 1991. Additionally, this is a continuation-in-part of Ser. No. 07/966,095 now issued as U.S. Pat. No. 5,550,691, which was filed on Oct. 22, 1992 and issued on Aug. 27, 1996 which is a continuation-in-part of U.S. patent application Ser. No. 07/783,509 (now abandoned) filed Oct. 28, 1991. Further, this is a continuation-in-part of U.S. patent application Ser. No. 07/783,619 now issued as U.S. Pat. No. 5,490,027 filed on Oct. 28, 1991 and issued on Feb. 6, 1996. This is also a continuation-in-part of U.S. patent application Ser. No. 08/179,758 (now abandoned) filed on Jan. 7, 1994, which is a continuation of U.S. patent application Ser. No. 07/684,025 (now abandoned) filed on Apr. 10, 1991. This is also a continuation-in-part of U.S. patent application Ser. No. 08/017,984 (now abandoned) filed on Feb. 12, 1993, which is a continuation from U.S. patent application Ser. No. 07/770,593 (abandoned) filed on Oct. 3, 1991. This is also a continuation-in-part from U.S. patent application Ser. No. 08/180,540 (now abandoned) filed Jan. 12, 1994, which is a continuation-in-part from U.S. patent application Ser. No. 07/760,586 (now abandoned) filed Sep. 16, 1991. The following U.S. patent applications and patents are incorporated by reference into this application: application Ser. No. 07/911,680, U.S. Pat. No. 5,041,932, application Ser. No. 07/990,005, application Ser. No. 07/746,916, application Ser. No. 07/966,095, U.S. Pat. No. 5,550,691, application Ser. No. 07/783,509, application Ser. No. 07/783,619, U.S. Pat. No. 5,490,027, application Ser. No. 08/179,758, application Ser. No. 07/684,025, application Ser. No. 08/017,984, and application Ser. No. 07/770,593. 
     
    
     
       FIELD OF INVENTION  
         [0002]    The present invention relates to electromagnetic read/write, information storage and retrieval systems, and in particular, to the structural merging in such systems of electrical and mechanical functionality, and to ancillary matters that surface as structural, organizational opportunities as a result of such merging. Recognizing that the various features of the invention can have important applicability in a wide range of kinds of such systems (e.g., rigid-disk, floppy-disk, drum, tape, etc. systems), the description which follows herein focuses attention on rigid-disk systems—an arena which is most central in today&#39;s commercial applications. Accordingly, specification and claim references made herein to rigid disks should be read to include these other-kinds-of-media systems.  
           [0003]    Given the merged-functionality aspect of the present invention, many features thereof, accordingly, focus upon improvements in mechanical load-bearing and in motion-articulating characteristics of transducers, and of flexures which carry such transducers, that are used in these kinds of systems. In this context, the field of the invention encompasses systems wherein (a) a read/write transducer flies over a media recording surface, (b) such a transducer is intended for contact-capable operation, and operates with intermittent media-surface contact, and (c) such a transducer is intended for contact-capable operation, and operates in substantially continuous contact with a media recording surface.  
         BACKGROUND AND SUMMARY OF THE INVENTION  
         [0004]    In the march of progress which has characterized ongoing development of disk-drive, electromagnetic read/write systems, the quests for enlargement of areal recording density, and for improved-quality read/write signal communication between a disk&#39;s recording surface and a transducer, have been high on the list of technical interest and relentless pursuit. This situation has been reflected, inter alia, in significant reductions in components&#39; sizes and masses, by reductions in the “effective masses” of those components which react dynamically during read/write operations, and in dramatic reduction in the separation which exists between the working read/write zone of a transducer and a disk&#39;s recording surface. These advances include, according to an important line of development by the Censtor Corporation of San Jose, Calif., system embodiments in which a read/write transducer operates in substantially continuous sliding contact with such a recording surface. The latter line of advancement in the art of disk-drive recording is well illustrated and expressed in the parent patent and patent applications which have been set forth hereinabove.  
           [0005]    Pausing for a moment at this point to focus upon prior art efforts by others to bring about size reductions, it is important to bear in mind that these prior art changes have, by and large, been accomplished with what might be thought of as a segregated rather than a merged focus upon the three core functionalities—electrical, mechanical and magnetic—of read/write transducers and supporting flexures. In other words, prior art thinking has looked upon the respective components in this environment which offer each of the individual functionalities as being essentially independent of the other-functionality components. As a consequence, there has been somewhat of a naturally perceived limit in how far one can go to bring about significant size reduction—a limit dictated by functional performance constraints, and even more appreciably, probably, by manufacturing-costs and manufacturing-capabilities constraints.  
           [0006]    Specifically, and looking for a moment just at the issue of mechanical load bearing, prior art thinking has been based upon the notion that once necessary mechanical load-bearing requirements are known, all of that structure which has been looked upon in the past as being the sole constituent attending to that functionality can only be reduced in size just so much if it is to remain practically manufacturable. However, beginning with the work of Hal Hamilton as such is expressed in the above-referred-to &#39;932 patent, a new kind of thinking has entered this art, whereby “merger of functionality” is viewed as providing an opportunity for retaining all necessary electrical, mechanical and magnetic capability, while at the same time allowing for substantial shrinking of overall size, and actual improvement in practical manufacturability. More particularly, in the Hamilton &#39;932 disclosure, there surfaces a recognition that electrical current-carrying structure can be utilized significantly to carry mechanical load, and conversely, that mechanical load-bearing structure can be utilized significantly to carry electrical current. In other words, what might be thought of as singular-character structure, or material, functions in multiple ways. Not only does this unique way of thinking about merged-functionality yield surprising size- and mass-reduction opportunities, but also it tends to lead toward structures which are inherently simpler in form and in construction, and less complex and costly to fabricate.  
           [0007]    It is this “merged-functionality” view which underlies key contributions made to the art by the present invention.  
           [0008]    Continuing, and directing attention to other matters upon which this invention is focussed, in the ever more intimate environment of the interface between a disk&#39;s recording surface and a read/write transducer, and in addition to the size, mass, effective mass and spacing issues just generally expressed, many other considerations sit as important participants at the table of key technical concerns. For example, tight control over, and maintenance of, a very precise XYZ spatial location of a transducer in relation to a disk surface is critical, as is the ability of the transducer and supporting flexure structure to respond rapidly and fluidly to disk-surface topographical features, and/or to other things and events which require speedy, accommodating, operating-attitude adjustment. This kind of adjustment must take place in a manner minimizing as much as possible any occasions of signal-communication drop-out, and in a manner free of disruptive resonance vibrations. Attention also must be addressed to damping and shock-absorbing issues.  
           [0009]    All of these considerations need to be taken into account as well (a) in systems where a transducer flies over a disk&#39;s recording surface, (b) in systems where contact operation occurs (intermittently or continuously), and (c) in systems which, on the one hand, have gimbaled transducer structures, and on the other hand, non-gimbaled transducer structures.  
           [0010]    In the gimbaled transducer setting, the merged functionality focus aspect of the invention opens the door to the fabrication and use of a load-bearing transducer chip which has a substantially planar body, with plural, projecting disk-surface contact feet, or pads, and which can operate, relative to a disk&#39;s recording surface, with substantially a zero-angle-of-attack, and with the read/write portion of the transducer in intimate contact with that surface. This, in turn, offers the opportunity for electromagnetic design which occupies space in the plane of the body, and which allows for placement of the read/write zone anywhere relative to that body.  
           [0011]    Given the above remarks and comments, it is an important object of the present invention to offer transducer/flexure improvements along the lines just suggested—focused on the notion of structural merging, for example, of electrical and mechanical functionality.  
           [0012]    A related object of the invention is to provide such improvements which lead toward simple, low-cost, low-mass structures that offer the opportunity for appreciable enlargement in areal density of recorded information, with reliable and improved signal-communication characteristics.  
           [0013]    Thus, an important object is to provide a head/flexure structure which includes load-bearing (merged-functionality) conductors.  
           [0014]    A related object is to provide a head/flexure structure in which the conductors perform mechanical functions in addition to their function of conducting electrical signals between a head and other circuitry.  
           [0015]    Still another object of the invention disclosed herein is to provide a flexure/conductor structure which supports a head in a precise location and orientation relative to the surface of a medium.  
           [0016]    Yet a further invention object is for the head-supporting flexure to be capable of supporting the head in a contacting relationship with the disk while reading or writing, without the occurrence of catastrophic head crash events or excessive interface wear.  
           [0017]    Also, an object of the invention is to provide a flexure/conductor structure which is capable of moving, the head along a Z-axis, i.e., that axis which is normal to the surface of the disk, with a minimal degree of angular rotation, i.e., minimizing the angular constant.  
           [0018]    Another object is to provide a flexure/conductor structure which exhibits maximum levels of lateral and torsional resonant frequencies with the minimal amount of gain.  
           [0019]    Still a further object is to provide a transducer/flexure/conductor structure which has a minimal number of parts, and which can be produced by a relatively straight-forward and cost-effective process, including, in certain cases, an automated assembly process.  
           [0020]    Another object is to provide a flexure/conductor structure which is capable of compensating for topographical irregularities in the surface of the recording medium.  
           [0021]    Yet another object of the invention is to provide a flexure/conductor structure in which the head is allowed a certain range of pitch and roll movement independent from the flexure.  
           [0022]    A further object is to provide a head/flexure structure which has a tunable hinge near its proximal end.  
           [0023]    Other objects include providing a head/flexure structure which: (a) is wireless; (b) is amenable to compact disk-to-disk stacking; and (c) contains more than one pair of conductors.  
           [0024]    Still a further object is to provide a head/flexure structure which has a gimbal including conductive articulators.  
           [0025]    Thus, the inventive subject matter presented herein regards improvements in transducer/flexure structure for an electromagnetic read/write system, and relates, inter alia, to structures, such as flexures, for carrying electromagnetic read/write transducers, and more particularly, to such structures wherein electrical conductors which connect with such transducers are utilized significantly, in an augmentive way, as mechanical load-bearing and articulating elements in the structures. The subject matter of the invention also relates to contact-capable read/write systems in which the read/write transducer acts directly as a load-bearing structure under disk-contact conditions. According to an important aspect of the invention, therefore, such augmented-role conductors play the dual roles of (a) conducting electrical signals between a transducer and remote, external circuitry, such as a signal processor, and (b) at the same time supporting mechanical load (such as a bending and/or articulating load), including, in certain embodiments, 100% of that load in a certain portion or region of a transducer-carrying structure.  
           [0026]    Fundamentally, the subject matter of the present invention rests on several key concepts, some of which spring from the notion that innovation in the load-carrying/articulation characteristics of transducer-carrying structure can significantly enhance overall read/write system performance. One of these concepts—based upon a new and striking “merged-functionality” recognition—is that the very same conductors which carry signal-bearing information to and from a read/write transducer can also function mechanically as the articulating and load-bearing beam structure which carries and supports such a transducer, statically and dynamically, for instance, in the setting of a cantilever-type support arrangement for a disk read/write transducer. This conceptual thought carries also into an arrangement where, effectively, the transducer is supported for gimbaling action, with the recognition that what might be thought of as the gimbal articulators (hinges or torsional beams) can be formed by electrical-current-carrying conductors.  
           [0027]    Another foundation concept is that the flexure/beam transducer-carrying construction can take important advantage of what can be viewed as bilateral motion independence, wherein a pair of spaced beam components afford a single- or dual-axis articulation capability to a supported transducer. Indeed, such construction can enable dual-degree-of-motion gimbal action (as just suggested above) for such a transducer. The shift of mechanical articulation and load-bearing responsibilities to signal-carrying conductors is an especially useful concept in so-called micro-flexure designs where extremely small mechanical structures are involved.  
           [0028]    A further important concept is that a read/write transducer can itself be utilized as a load-bearing structure—a concept leading, inter alia, toward minimizing of the size and mass of the overall transducer/flexure/conductor structure.  
           [0029]    In addition to the structural contributions made by the present inventive subject matter, also furnished thereby are novel methods of producing micro-transducer-support structures employing signal-carrying conductors as mechanical load-bearing/articulating elements such, for example, as hinges, torsional beams, etc.  
           [0030]    These and other objects, advantages and features that are offered by the present invention will become more fully apparent as the description which now follows is read in conjunction with the accompanying drawings. 
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0031]    [0031]FIGS. 1A and 1B are views of a transducer/flexure which is disclosed and claimed in U.S. Pat. No. 5,041,932. FIG. 1A is a side view of the transducer/flexure, loaded on a disk, in relation to an XYZ coordinate system. FIG. 1B is a cross-sectional view of the flexure shown in FIG. 1A, with this view being taken generally along line  1 B- 1 B in FIG. 1A.  
         [0032]    [0032]FIG. 2 is an exploded perspective view of a tapered transducer/flexure structure with load-bearing conductors and a hinge.  
         [0033]    [0033]FIG. 3A is a top view of the transducer/flexure shown in FIG. 2.  
         [0034]    [0034]FIG. 3B is a partial side view of the distal end of the transducer/flexure shown in FIG. 3A.  
         [0035]    [0035]FIG. 3C is a bottom view of the transducer chip shown in FIG. 3B.  
         [0036]    [0036]FIG. 3D is an enlarged, fragmentary view of the area in FIG. 3B embraced by curved arrows  3 D- 3 D, illustrating a modified form of transducer pole and coil structure.  
         [0037]    [0037]FIG. 4 is a partial top view of a flexure, focusing on the hinge region.  
         [0038]    [0038]FIG. 5A is a cross-sectional view of the flexure shown in FIG. 3A.  
         [0039]    [0039]FIGS. 5B and 5C are cross-sectional views of flexures with load-bearing conductors and additional damping and constraining layers.  
         [0040]    [0040]FIG. 6 is a partial side view of the flexure shown in FIG. 3A, focusing on the hinge region.  
         [0041]    [0041]FIG. 7 is a schematic partial view of a flexed beam with an intervening adhesive resin layer.  
         [0042]    [0042]FIG. 8 is an exploded perspective view of a transducer/flexure with four conductors, and a hinge near the proximal end of the flexure.  
         [0043]    [0043]FIG. 9 is a top view of the transducer/flexure shown in FIG. 8, assembled. Conductor boundaries, which are covered by stiffeners, are indicated by dashed lines.  
         [0044]    [0044]FIG. 10 is an exploded perspective view of a transducer/flexure with load-bearing conductors and a load-button gimbal.  
         [0045]    [0045]FIG. 11 is a perspective view of the transducer/flexure shown in FIG. 10, assembled except for mounting of the chip (transducer).  
         [0046]    [0046]FIG. 12A is a top view of the transducer/flexure shown in FIGS. 10 and 11. Conductor boundaries, which are covered by stiffeners, are indicated by dashed lines.  
         [0047]    [0047]FIG. 12B is a partial side view of the distal end of the flexure shown in FIG. 12A.  
         [0048]    [0048]FIG. 12C is a bottom view of the transducer shown in FIG. 12B.  
         [0049]    [0049]FIG. 13 is an exploded perspective view of a transducer/flexure with load-bearing conductors, a hinge near the proximal end of the flexure and a gimbal near the distal end of the flexure.  
         [0050]    [0050]FIG. 14 is a partial top view of the conductors shown in FIG. 13, focusing on the distal ends of the conductors, specifically, the conductor gimbaling structure.  
         [0051]    [0051]FIG. 15A is a top view of the transducer/flexure shown in FIG. 13, assembled.  
         [0052]    [0052]FIG. 15B is a partial side view of the transducer/flexure shown in FIG. 15A.  
         [0053]    [0053]FIG. 15C is a bottom view of the transducer shown in FIG. 15B.  
         [0054]    [0054]FIG. 15D is a partial side view of the distal end of a gimbaled transducer/flexure with a modified transducer and pad configuration.  
         [0055]    [0055]FIG. 15E is a bottom view of the transducer shown in FIG. 15D.  
         [0056]    [0056]FIG. 16 is a thin-layer sectional view of the flexure shown in FIG. 15A.  
         [0057]    [0057]FIG. 17A is a partial top view of the distal end of the transducer/flexure shown in FIG. 15A, with the addition of a membrane damping layer in the vicinity of the gimbal.  
         [0058]    [0058]FIG. 17B is the same as FIG. 17A except the damping layer is localized over four discrete regions of the gimbal.  
         [0059]    [0059]FIG. 18 is a partial top view of the distal end of a transducer/flexure with a membrane which functions primarily as a gimbal structure.  
         [0060]    [0060]FIG. 19A is a top view of a transducer/flexure with load-bearing conductors, two hinges and a modified gimbal.  
         [0061]    [0061]FIG. 19B is a partial top view of the distal ends of the conductors in the transducer/flexure shown in FIG. 19A.  
         [0062]    [0062]FIG. 20 is a side view of the transducer/flexure shown in FIG. 19A, operating on a disk.  
         [0063]    [0063]FIG. 21 is a top view of a transducer/flexure, similar to the one shown in FIG. 19A, except that conductor dimensions are modified.  
         [0064]    [0064]FIG. 22A is a side view of the transducer/flexure shown in FIG. 21, with a pre-bend near the proximal end of the flexure. The flexure is shown in its pre-loaded position (solid lines) and in its operating or loaded position (dash-dot lines).  
         [0065]    [0065]FIG. 22B is a partial top view of a flexure which is similar to the flexure shown in FIG. 21, except that it employs a modified gimbal.  
         [0066]    FIGS.  23 - 25  are top views of modified two-conductor gimbaling structures.  
         [0067]    [0067]FIG. 26 is a top view of a modified four-conductor gimbaling structure.  
         [0068]    [0068]FIG. 27A is a partial top view of a two-conductor gimbaling structure that forms part of a transducer/flexure which employs hinges to allow roll and pitch movement of the chip.  
         [0069]    [0069]FIG. 27B is a partial top view of the gimbaling structure shown in FIG. 27A, with the addition of stiffening layers.  
         [0070]    [0070]FIG. 28A is a top view of a first embodiment of a torsionally compliant transducer/flexure.  
         [0071]    [0071]FIG. 28B is a side view of the transducer/flexure shown in FIG. 28A.  
         [0072]    [0072]FIG. 29A is an exploded perspective view of a second embodiment of a torsionally compliant transducer/flexure, with a pitch gimbal mechanism.  
         [0073]    [0073]FIG. 29B is a top view of the transducer/flexure shown in FIG. 29A.  
         [0074]    [0074]FIG. 30 is a top view of a third embodiment of a torsionally compliant transducer/flexure with a pitch gimbal.  
         [0075]    [0075]FIG. 31 is an exploded perspective view of a dual-cantilever transducer/flexure with four conductors and four hinges.  
         [0076]    [0076]FIG. 32 is a perspective view of the transducer/flexure shown in FIG. 31, assembled.  
         [0077]    [0077]FIG. 33 is a side view of the transducer/flexure shown in FIGS. 31 and 32. The flexure is shown in its pre-bent unloaded position (solid lines), and in its loaded or operating position (dash-dot lines).  
         [0078]    [0078]FIG. 34A is an exploded perspective view of another dual-cantilever transducer/flexure.  
         [0079]    [0079]FIG. 34B illustrates the transducer/flexure of FIG. 34A, assembled.  
         [0080]    [0080]FIG. 34C is a schematic side view of the transducer/flexure shown in FIGS. 34A and 34B, in its unloaded position (dash-dot lines) and operating position (solid lines).  
         [0081]    [0081]FIG. 35 is an exploded perspective view of another transducer/flexure embodiment.  
         [0082]    [0082]FIG. 36A is an exploded perspective view of still another dual-cantilever transducer/flexure embodiment.  
         [0083]    [0083]FIG. 36B is a partial side view of the distal end of the transducer/flexure shown in FIG. 36A.  
         [0084]    [0084]FIG. 37A is a schematic side view of a disk-contacting mount configuration supporting a transducer/flexure in its operating position.  
         [0085]    Each of FIGS. 37B and 37C is a top view of a transducer/flexure of the present invention including an alternative gimbal design.  
         [0086]    [0086]FIG. 38A is a schematic side view of a flexure mounting system showing disk-to-disk spacing with respect to an E-block and mounted flexures.  
         [0087]    [0087]FIG. 38B is a schematic side view of a modified flexure mounting system employing dual-cantilevers to permit closer disk-to-disk spacing.  
         [0088]    [0088]FIG. 38C is a partial side close-up view of one of the flexures and dual-cantilever mount structures shown in FIG. 38B.  
         [0089]    [0089]FIG. 39A is a schematic top view of a transducer/flexure mounted on a nut plate and including a two-conductor configuration with versatile, redundant connective tabs on opposite sides with the proximal end of the flexure/nut-plate structure.  
         [0090]    [0090]FIG. 39B is a schematic side view of four flexure/nut-plate structures as shown in FIG. 39A, mounted in an E-block and electrically connected to a flex cable.  
         [0091]    [0091]FIG. 39C is a schematic top view of another nut-plate/flexure embodiment with versatile, redundant connector conductor tabs.  
         [0092]    [0092]FIG. 40A is a top view of a gimbaled flexure embodiment which is dimensioned to operate under a minimal load.  
         [0093]    [0093]FIG. 40B is a top view of the conductor configuration employed in the flexure shown in FIG. 40A.  
         [0094]    [0094]FIG. 40C is an enlarged partial top view of the flexure shown in FIG. 40A.  
         [0095]    [0095]FIG. 40D is a schematic side view of a transducer/flexure with a pre-bend near its distal end.  
         [0096]    FIGS.  41 - 45  are schematic top view layouts of sheet intermediate materials used in a production method of the present invention.  
         [0097]    [0097]FIG. 46 is a top view of a flexure resulting from the process illustrated in FIGS.  41 - 45 . Relative dimensions of the final flexure structure are shown.  
         [0098]    FIGS.  47 - 49  are schematic top view layouts of sheet intermediate materials used in another production method of the present invention.  
         [0099]    [0099]FIGS. 50A and 50B show working-side views of two modified forms of transducer chips. 
     
    
     DEFINITIONS  
       [0100]    Terminology in the specification and claims should be interpreted in accordance with the following definitions.  
         [0101]    A “flexure” is a flexible cantilever beam, with or without gimbal structure, for supporting a transducer adjacent a medium. A “suspension” may refer to a flexure, either alone or together with a flexure mounting system.  
         [0102]    A “transducer” is an electromagnetic working organization, or unit, employed typically near the distal end of a flexure directly adjacent a medium in a read/write system. The transducer includes pole and coil substructures and the embedding material surrounding the substructures. A pole has a read/write working region. As used herein, the transducer does not include ancillary joined structure such as air bearing rails in a conventional flying slider. In at least one embodiment of the invention, the transducer is provided as an integrated component of the flexure. In other embodiments, the transducer is in the form of a chip which is joined to the distal end of the flexure. Each transducer has a working side which faces the recording surface in a magnetic medium during normal read/write operations.  
         [0103]    At various locations throughout this specification reference is made selectively to the top and bottom sides of different structures. Where these terms are applied to a disk surface, it is assumed that the related disk is operating in a horizontal plane. Where these terms are applied to flexure, beam, transducer structures inside of the transducer, and top side refers to the opposite side.  
         [0104]    The “Z-axis” is perpendicular to the surface of a recording medium and extends vertically through a transducer mounted on the free end of a flexure. A limited range of movement of the transducer along the Z-axis is allowed, as the transducer follows disk surface topography, during and between reading and writing activity. An “X-axis” and a “Y-axis” share a common origin with the Z-axis at the center of the distal edge of the transducer, and are perpendicular to each other in a plane which is co-planar with the upper-most surface of the medium when the transducer is operating in contact with this surface. The Y-axis is generally “longitudinal”, i.e., parallel to the length of the flexure. The X-axis is generally “lateral”, i.e., parallel to the width of the flexure. The X, Y and Z axes are illustrated in FIG. 1A relative to the distal tip of a transducer/flexure  60 . The point of contact  62  between the transducer and disk  64  coincides with the origin of the coordinate system.  
         [0105]    “Roll”, “pitch” and “yaw” refer to particular types of inclinational movement of a transducer relative to its static or idealized suspended position adjacent the surface of a medium. “Roll” refers to rotational movement about the Y-axis of a transducer adjacent the surface of a recording medium. “Pitch” refers to rotational movement around the X-axis of a transducer adjacent the surface of a recording medium. “Yaw” refers to rotation around the Z-axis of a transducer adjacent the surface of a recording medium.  
         [0106]    “Load-bearing” is defined and used, inter alia, in the context of a cantilever flexure which has a mounting end and a free end extending generally horizontally over (adjacent) the surface (upper or lower) of a recording medium, for example, a rigid disk. The free end of the flexure supports and positions a transducer for reading and writing information on the surface of a medium. By deflection, the free end (distal end) of the flexure is applied by a force (load) against either the surface of the medium or an air-bearing directly on top of the surface. Elements of the flexure which provide significant support for the load, i.e., maintenance of desired Z-axis position of the transducer, are referred to as “load-bearing” structures. “Load-bearing” also relates to “articulation” (defined below) structure.  
         [0107]    A “beam” is a transverse structural member which provides partial or complete support for a transducer adjacent the surface of a recording medium. The term “beam” may be used referring to the entire flexure body, or a load-bearing component of the body.  
         [0108]    “Anisometric” means inequality of measurements or properties. The tern is used in this application with reference to a beam&#39;s axis-differentiated bending stiffness—i.e., regarding a beam having a preferential bending axis.  
         [0109]    “Articulation” is used with respect to two structural members (sometimes referred to as “arms”) which are linked together, but allowed a certain degree of movement relative to each other. An “articulator” is a semi-rigid structure connecting first and second parts, which permits a selected range and type of mechanical movement of the parts relative to each other. An “articulating conductor” is an electrical conductor which also functions as an articulator. A “hinge articulator”, also referred to as a “beam/articulator structure”, is an articulator (unit, element) which bends around an axis perpendicular to a line centrally and directly connecting the two parts (also referred to as a “longitudinal axis”). A “torsional articulator” is an articulator (unit, element) which twists around an axis centrally and directly connecting the two parts (longitudinal axis). A “torsional beam” is a torsional articulator. A “mixed-mode articulator” (unit, element) is a hybrid of a hinge articulator and a torsional articulator.  
         [0110]    “Hinge” is a connector between two parts which allows a degree of movement, i.e., bending, of the parts relative to each other.  
         [0111]    “Proximal” is used to refer to the end vicinity of a flexure which is structurally anchored or secured to a read/write system frame or servo-control actuator. The proximal end of the flexure is also referred to as the “mounting end”.  
         [0112]    “Distal” is used to refer to the end vicinity of the flexure which carries the transducer and is also referred to as the “free end”.  
         [0113]    “Angular constant” is defined, relative to a cantilever flexure, as the degree of angular change at the distal tip of the flexure for a given deflection.  
         [0114]    A “pad” (also referred to as an island) projects from a side or face of a flexure or a transducer chip and contacts the surface of a disk when the transducer/flexure is operating to read or write information from the disk. With respect to flexures which employ gimbals, a triangular organization of three pads is sometimes used, and referred to as a “tri-pad” or “trident” structure.  
       DETAILED DESCRIPTION OF INVENTION  
       [0115]    The invention, resting strongly on the merged-functionality concept set forth above, involves load-bearing and articulating structures for use in suspensions relating to micro-flexures which support transducers in electromagnetic read/write systems. These structures take the forms of load-bearing conductors and transducers, hinge-like mechanisms, torsional beams, and flexure mounting systems which allow production and implementation of flexures with low angular constants, minimum mounting tolerances, and/or the capability of tolerant compliance of the transducer with an inherently irregular recording medium surface. An important aspect of some of the transducer/flexures disclosed and claimed in the present invention is the use of electrical conductors and transducers which are geometrically designed and arranged to provide load-bearing support, as well as articulable movement, between linked portions of the flexure body.  
         [0116]    [0116]FIGS. 1A and 1B illustrate a micro-flexure  60  (flexure/conductor/transducer structure), including an integrated transducer, or transducer unit, which was originally described and claimed in parent U.S. Pat. No. 5,041,932. The transducer, which is a tiny portion of the overall structure pictured in FIG. 1A, is located at the distal tip shown at  62 . This transducer includes magnetic pole structure and coil and conductor structure all embedded in a small volume of surrounding joinder structure. It is in the disclosure of the &#39;932 patent that the notion of merged-functionality makes its important debut in the read/write, disk drive transducer/flexure context. It is also in the &#39;932 patent that one finds the introduction of a load-bearing transducer unit. Reference to the text and drawings of the patent will reveal a novel transducer unit having pole structure unified with (and within) a disk-contacting wear pad (or projection), and generally planarly distributed, coupled coil structure which extends generally in a plane parallel with the plane of the wear pad&#39;s disk-contacting face.  
         [0117]    As shown in FIGS. 1A and 1B, micro-transducer/flexure  60  includes integrated load-bearing conductors  61   a  and  61   b  embedded within flexure  60  along its entire length (continuum structure). An integrated transducer is embedded within flexure  60  at its distal tip  62  where it contacts disk  64  during operation of the read/write system. A number of important features of the present invention, which are more extensively developed in the embodiments illustrated and described below, are fully present in the micro-transducer/flexure structure illustrated in FIGS. 1A and 1B. First, as shown in FIG. 1B, integrated conductors/beams  61   a  and  61   b  are massive enough relative to the entire flexure body  60  to support a significant portion of the cantilever load. According to the teachings of the &#39;932 patent, conductors  61   a ,  61   b  occupy in the range of about 13% to about 40% of the full thickness of the body of flexure  60 . Therefore, conductors  61   a  and  61   b  play a dominant mechanical role, and are referred to as “load-bearing conductors”. Another important physical attribute of conductors/beams  61   a  and  61   b  is their generally rectangular or “blade-like” cross-sectional shape which provides preferential (anisometric) bending, allowing the tip to move in a direction along the Z-axis. The blade-like shapes of conductors  61   a  and  61   b  are also contributors to a relatively high lateral-frequency characteristic for flexure  60 . Still another interesting geometric feature of conductors  61   a  and  61   b  is their symmetrical organization about plane W which bisects flexure  60  along its length. Between their opposite sets of ends, these conductors are also referred to as substructure spans.  
         [0118]    A second important load-bearing structure embodied in the transducer/flexure of FIG. 1A, as briefly mentioned earlier, is the transducer itself (the embedded pole structure and coil and conductor structure mentioned earlier) located at the distal tip of flexure  60 . Unlike flexures/transducers in the prior art, such as transducers joined to massive load-bearing, sliders, in which the transducer carries essentially none of the deflected beam load, the transducer integrated in the distal tip of flexure  60  directly contacts disk  64  and carries 100% of the cantilever load—i.e., directly through the embedded pole, coil, and conductor structure. The uses of load-bearing conductors and a load-bearing transducer in a transducer/flexure device, provide examples of a major theme of the present invention, namely, to design multi-functional (i.e., merged-functionality) components so that structures, such as conductors and transducers, which traditionally have had no mechanical function in prior art devices, become “mechanical activists” in the present invention, in addition to playing their traditional roles of conducting electrical signals and handling magnetic flux.  
         [0119]    A related micro-flexure structure  70  with load-bearing conductors, or conductor elements, and a proximal hinge, or hinge region, is illustrated in FIG. 2. Micro-flexure  70  includes two, relatively flat, blade-like conductors (continuum structure)  72  and  74 . Conductors  72  and  74 , which form a common conductive layer, are insulated from each other by space  75 . Conductors  72  and  74 , collectively, have a tapered shape, and are widest at proximal (mounting) end  76  and narrowest at distal (free, disk-confronting, transducer-carrying) end  78 . End  76  is also referred to herein as a base region. A proximal stiffener layer, or stiffener,  80  overlays the proximal ends  76  of conductors  72  and  74 . Stiffener  80  has a hole  82  centrally located above a hole  84  defined by conductors  72  and  74 . Holes  82  and  84  are used for alignment of the suspension to a mounting surface in a disk-drive system. A rectangular window  86  in stiffener  80  provides access to the top sides of conductors  72  and  74  for electrical bonding. Distal and proximal bonding regions of conductors  72  and  74  are preferably gold plated. A second stiffener  88  extends from a “hinge region”  89  near the proximal end of the flexure, to the distal end of the flexure. Hinge region  89 , defined by the gap between stiffeners  80  and  88 , is shown more completely in FIG. 3A, FIG. 4 and FIG. 6. The structural regions located longitudinally on opposite sides of the gap are also referred to herein as arms. Four windows  90  in stiffener  88  provide access to the conductors for heating them in the process of connecting a transducer chip  92  to the bottom side of conductors  72  and  74 . Chip  92  contains, for example, a probe-type read/write transducer (not illustrated), the probe in which extends toward the disk&#39;s recording surface through a single, projecting contact (wear) pad, or projection,  97  (see FIG. 3B).  
         [0120]    A top view of flexure  70  is illustrated in FIG. 3A. Conductors  72  and  74  are seen in hinge region  89  where they are separated by a gap  75 . In addition to being tapered from hinge region  89  to the distal end of flexure  70 , lateral edges  94   a  and  94   b  in the flexure are slightly concave—a design feature which has been found to yield improved (higher) torsional frequency characteristics.  
         [0121]    Hinge region  89  of flexure  70  has the following preferred specifications. Conductors  72  and  74  and stiffeners  80  and  88  are type-302 (or type-304) stainless steel. The thickness of the hinge material, i.e., conductors  72  and  74 , is 0.5-mils. (1 mil.={fraction (1/1000)}-of-an-inch). The length of the hinge is 24-mils. These dimensions were selected for the purpose of maintaining a spring constant of approximately 2.5-mgs.-per-mil. Stiffeners  80  and  88  are 1-mil. thick. Thus, most of the bending which occurs when the flexure is deflected, occurs in hinge region  89 .  
         [0122]    The hinge design just described provides a number of important benefits. First, a lower angular constant is achieved relative to a non-hinged design. Optimal angular constant for a simple cantilever, such as the one illustrated in FIGS. 2 and 3A, is achieved when all the bending occurs at the base (i.e., a perfect hinge). In the flexure shown in FIGS. 2 and 3A, most of the bending occurs in the base 7% of the beam. This results in an angular constant of approximately 0.19°-per-mil. of deflection. Second, the hinge provides damping capability. Since most of the flexure is rigid, constrained-layer (electrically insulating) damping material, as illustrated in FIGS. 5A, 5B and  5 C (discussed in detail below), can be added to the stiffened region without affecting the spring constant. The damping material can be positioned between the conductor and stiffener layers, and/or another set of damping and constraining layers can be added above or below the flexure if necessary to attenuate vibrational amplitudes. Third, the hinge provides improved drive tolerances. If a pre-bend is added to the hinge area of the flexure, the suspension can operate essentially flat—thus requiring less mounting space. This allows very close disk-to-disk spacing. Structures, considerations and benefits relating to the concepts of pre-bent flexures and disk-to-disk spacing will be more fully developed below.  
         [0123]    The trapezoidal/concave edge shape of the flexure, overall beam thickness, and 350-mil. free beam length provide the following advantages. First, the shape provides good lateral stiffness. Lateral stiffness increases as the cube of width. High lateral stiffness is desirable for minimizing lateral vibrational movement. Second, by tapering the width at the tip, high lateral frequencies are achieved which are desirable for servo stability. Third, the “bugle” or concave-edge shape was found to have the highest torsional frequency of trapezoidal-like shapes. High torsional frequency is desirable for servo stability because there can be a significant off-track motion associated with the torsional mode. Fourth, the design has been found to avoid undesirable modal interactions. We have discovered that certain normal modes of vibration interact with others, causing high vibrational amplitudes. Such interaction is caused by frictional changes at the transducer/disk interface with contact pad angle changes. Accordingly, the following situations should be avoided: (1) lateral frequency 1×, 2× or 3× the torsional frequency, and (2) torsional or lateral frequency of 1× or 2× any first or second bending frequency.  
         [0124]    [0124]FIG. 3B is a side view of the distal end of flexure  70 , illustrating the mounting of transducer chip  92  on flexure  70 . Stiffener  88  is separated from conductor  72  by an adhesive (bonding) layer  95 . Solder structures, plus adhesive and/or conductive epoxy structures in some cases, such as the solder structures shown at  96   a  and  96   b , electrically and mechanically connect conductor  72  to chip  92 . Full mechanical load is transmitted through these connections. Single pad  97  is preferably made of amorphous diamond-like carbon (DLC), and is positioned on the bottom side (in FIG. 3B) of chip  92 , near the center of its trailing edge, as shown in FIG. 3C. When transducer/flexure  70  is in its operating mode, pad  97  contacts the uppermost surface of disk (medium)  98 . The single-pad configuration which is employed in transducer/flexure  70  and illustrated in FIGS. 3B and 3C is characteristic of the flexures shown in FIGS.  1 - 9 , which do not include gimbals. When a single pad is employed in a non-gimbaled flexure, facets are polished around the pad to provide full transducer signal through a range of static mounting tolerance. Other pad configurations and considerations are discussed below. Similar to the integrated transducer/flexure structure shown in FIGS. 1A and 1B, transducer chip  92 , as shown in FIG. 3B, bears the entire cantilever load of the deflected beam. Thus, the need for a separate load-bearing structure is avoided.  
         [0125]    In the configuration shown in FIG. 3B, chip  92  contains transducer pole structure and coupled coil structure organized and distributed in the following fashion. The read/write working portion of the pole structure extends within pad  97  to the bottom (in FIG. 3) disk-contacting face of the pad. The coupled coil structure occupies the generally horizontal (in FIG. 3) plane of the main body of the chip.  
         [0126]    Shifting focus briefly onto the modification shown in FIG. 3D, here chip  92  contains pole structure and coil structure organized and distributed in a somewhat different manner. Specifically, here, both of these structures occupy a plane which extends generally normal to the long axis of flexure  70 . This planar region is indicated generally at  99 . Here too the read/write working portion of the pole structure extends within pad  97  to the bottom face of the pad. This organization is referred to as a “pin head” type arrangement.  
         [0127]    The FIG. 3D embodiment suggests the possibility of creating yet another kind of transducer chip which is fully planar, and intended for suitable mounting at the end of a beam/flexure, in a disposition with its plane, including the plane of the body of the chip, normal to the long axis of the beam/flexure. Such a situation is specifically illustrated and described in a portion of this specification set forth below. In all cases the transducer is load-bearing.  
         [0128]    The performance or flexibility of the hinge region can be modified or tuned by, for example, altering the dimensions of the conductors in the hinge region, or by changing the width of the gap between stiffeners, as illustrated in FIG. 4. Here, for example, an illustrated hinge  100  includes conductor portions  102  and  104  flanked by stiffeners  105  and  106 . Flexibility of conductor portions  102  and  104  in the hinge region can be altered or tuned by changing the gap width. For example, if the hinge gap edge is relocated to line  109 , then hinge flexibility is increased. Similarly, other changes in conductor geometry or material composition provide different ways of tuning the hinge.  
         [0129]    [0129]FIG. 5A shows a cross section of flexure  70  as illustrated in FIG. 3A. Conductors  72  and  74  are separated by air gap  75 , and are bound to stiffener  88  via adhesive layer  95  (a resin). Stiffener  88  and layer  95  collaboratively form joinder structure for the conductors. Importantly, resin  95  functions to insulate conductors  72  and  74  electrically from stiffener  88 . Stiffening and/or vibrational damping can be enhanced by selecting an appropriate type, amount and application of the adhesive resin. Adhesive layer  95  is preferably 1.0-mil. thick. Adhesive resins which have been used to bond conductor and stiffening layers in laminant flexures of the present invention include epoxies, acrylics and polyimides in both liquid and sheet forms. For example a liquid epoxy resin available from Bondline, referred to as 6555™, can be used in the present invention. An epoxy resin in sheet form is available from AI Technology, referred to as TK7755™. An acrylic resin which can be used in the present invention is sold by DuPont under the trademark Pyralux™. A polyimide resin sold by DuPont under the name Kapton™ is another suitable alternative. Other good adhesive layer materials have been identified by Hutchinson Technology Incorporated which is located in Hutchinson, Minn.  
         [0130]    [0130]FIGS. 5B and 5C illustrate another feature of the invention which may be employed to provide vibrational damping in addition to any damping effect which may be achieved by resin layer  95  which is sandwiched between conducting and stiffening layers. In FIG. 5B, a damping layer  112  is continuously sandwiched between stiffener  88  and a constraining layer  114 , which, for example, may be stainless steel. Although it is possible to use a damping layer without a constraining layer, better results are obtained when the damping material is sandwiched between more rigid solids. This is because the damping effect relies on the absorption of shear energy in the damping layer. The amount of shear energy produced from vibrational motion of the flexure, and subsequently absorbed by the damping layer, is increased by using a constraining layer. FIG. 5C is the same as FIG. 5B except that it shows that damping layer  116  may be applied on the bottom side of the flexure, where it is sandwiched between conductors  72  and  74 , and constraining layer  118 . As shown in FIG. 5C, damping layer  116  spans gap  75  between conductors  72  and  74 . However, it is also possible for damping layer  116  to be omitted in the region of gap  75 , analogous to adhesive layer  95 . Conversely, it is possible for adhesive layer  95  continuously to span gap  75  between conductors  72  and  74 . A material known as ISD110™ or ISD112™, available from 3M Corporation, is suitable for damping layers  112  and  116 .  
         [0131]    [0131]FIG. 6 shows a side view of hinge region  89  of flexure  70 . Proximal stiffener  80  and distal stiffener  88  flank hinge region  89 . Resin layer  95  extends continuously in the region where stiffeners  80  and  88  overlay conductors  72  and  74 . Further considering some of the features which characterize hinge or hinge region  89 , within the elongate body of flexure  70 , the hinge region can be thought of as having longitudinal boundaries which are indicated in FIG. 6 by dash-dot lines  89   a ,  89   b . The conductor material which makes up hinge region  89  is homogeneous (outside of these two longitudinal boundaries) only with material which lies bounded between common (shared) spaced facial planes which intersect the regions of boundaries  89   a ,  89   b . These two common facial planes are illustrated by dash-dot lines  73   a ,  73   b  in FIG. 6. Another way of viewing this is that the material in hinge region  89  is homogeneous, beyond boundaries  89   a ,  89   b , only with extensions of the conductor material itself which makes up the hinge region.  
         [0132]    [0132]FIG. 7 schematically illustrates change in adhesive conformation due to flexure deflection. By selecting an appropriate type of resin, and by controlling the amount used, it is possible to vary the degree of stiffening obtained in the stiffened region. The type and amount of resin  95  can also be selected to provide an advantageous vibrational damping effect. Resins typically exhibit varying degrees of elasticity. In FIG. 7, rectangular resin section  132  is stretched into trapezoidal resin section  134  when the flexure is bent. A greater degree of stiffening is therefore achieved by selecting a resin which is relatively unyielding or resistant to stretching.  
         [0133]    [0133]FIGS. 8 and 9 illustrate views of a modified flexure, which in many respects is the same as the flexure shown in FIGS. 2 and 3A. An important difference, however, is that in the flexure shown in FIGS. 8 and 9, four conductors are provided in the conductive layer. It is sometimes necessary to provide more than two conductors to the distal end of the flexure. For example, in transducer/flexure structures which include a magnetoresistive read substructure, at least four conductors are required. FIGS. 8 and 9 illustrate that the concept of the present invention, characterized by multiple load-bearing conductors, may encompass designs which include many more than two conductors, even though most of the flexures specifically described in this application include only two load-bearing conductors.  
         [0134]    In FIG. 8, a flexure  140  includes a stiffener  142  and a stiffener  144  overlaying load-bearing conductors  146 ,  148 ,  150  and  152 . As in the previously described design, although not shown in FIG. 8, the stiffeners are bound to the conductors by an insulative adhesive resin. Transducer chip  154  is directly bonded to the bottom side of conductors  146 ,  148 ,  150  and  152 , substantially as shown in FIG. 3B. A single wear pad is provided on the bottom side of chip  154  near the center of its trailing edge. FIG. 9 shows the outline of the conductors in dashed lines. Note that in this structure, the conductors are distributed symmetrically with respect to an imaginary plane which bisects the flexure along its length.  
         [0135]    Turning attention now away from non-gimbaled structures made in accordance with the teachings of this invention toward gimbaled structures, it is important to note that gimbaled-type structures are fundamentally different from the flexure/transducer structures which have been described so far above. They are different in that gimbal mechanism allows the transducer chip ranges of pitch and roll motion independent from the supporting flexure body. Gimbaling movement of a transducer chip has been recognized as an extremely important mechanical feature with respect both to flying structures and to contact-capable structures. In the non-gimbaled flexures described above, the conductors have been characterized as “load-bearing” structures because of the relative size and configuration in a proximal hinge region and throughout the body or length of the flexure. In the descriptions which now immediately follow, gimbal flexures are described in which the conductors fulfill additional mechanical load-bearing and articulating functions, such as hinge and torsional flexibility for a distally-located gimbal which permits pitch and roll movement of the transducer chip relative to the flexure body. These gimbaled configurations are illustrated collectively in FIGS.  13 - 30 , inclusive, and in each of the designs therein illustrated, the conductors contribute functionally in at least three important ways: (1) to conduct electrical signals between a transducer and external circuitry; (2) to bear all or a portion of the deflected cantilever load, at least at some point along the length of the flexure; and (3) to provide a gimbal platform (a transducer-carrying platform) for mounting a transducer chip. Accordingly, the embodiments that are shown in the collection of figures just mentioned are referred to as “conductor gimbaling flexures”.  
         [0136]    A further matter to note is that in all of the flexure/transducer structures which are described and discussed in this specification, there exists, fundamentally, a three-layer flexure structure to which there is attached or joined, in various ways, a transducer chip. The three layers in each flexure structure include a conductor layer, an adhesive layer, and a stiffener layer, and in each of these layers, and in the different embodiments, the specific configurations of the components in the layer are somewhat different. Relying on the fact that all now-to-be-described flexure/transducer assemblies have, in many respects, similar organizational characteristics, descriptions of these embodiments will be presented in a more conversational flow of structural and functional qualities, rather than with a mechanistic listing of parts followed by a functional description, and with an effort to focus principally, and inter alia, on key differences that differentiate the different embodiments.  
         [0137]    Thus, and turning attention first of all now to FIGS. 10, 11,  12 A,  12 B and  12 C, here there is illustrated an embodiment of the invention which employs what is referred to as a “load-button” gimbal. This embodiment closely resembles a head/flexure design previously disclosed and claimed in co-pending U.S. application Ser. No. 07/783,619. Here a transducer/flexure  160  is principally supported by load-bearing conductors  162  and  164 . At the distal end of conductors  162  and  164  are articulator “ribbons”  166   a  and  166   b  on which a transducer chip  168  is mounted. A load button  170  is provided on the top side of chip  168  around which rocking, inclinational movement of the chip is allowed. It is important to note, however, that the load button could also be provided on the bottom side of stiffener  180  for example, by creating a downwardly protruding dimple. The height of load button  170  is approximately equal to the thickness (0.5-mils) of conductors  162  and  164  plus the thickness of adhesive layers  174  and  176 . Adhesive layers  174  and  176  facilitate lamination of stiffeners  178  and  180  on top of conductors  162  and  164 . FIG. 11 shows assembled flexure  160  with detached transducer chip  168 . FIG. 12A shows the top view of assembled flexure  160 .  
         [0138]    [0138]FIG. 12B illustrates the mounting configuration of transducer  168  on flexure  160 . In the region of flexure  160  where transducer  168  is attached, stiffener  180  is separated from conductor ribbon  166   b  by air. As shown in FIG. 10, adhesive layer  176  only extends distally to the point where ribbons  166   a  and  166   b  begin. Transducer  168  is bonded by solder structure  188   a  and  188   b  to conductor ribbon  166   b . The bottom side of transducer  168  has three wear pads  190   a ,  190   b  and  190   c  (see particularly FIG. 12C) which contact the disk surface in a triangular (tripodic) pattern when the transducer is operating. Ideally, sufficient load is applied to flexure to maintain contact between each of the pads and the disk surface at all times.  
         [0139]    In FIG. 13, flexure  200  includes conductors  202  and  204  which are spaced apart from each other and extend along the entire length of flexure  200 . A gimbal structure or region  206  of the conductors is located near the distal ends of the conductors. Each conductor contributes one of a pair of parallel platforms (or articulated portions)  208   a  and  208   b  which are located centrally within a cut-out gimbal region and serve collectively as a mounting platform for transducer chip  210 . This mounting platform is located adjacent what is also referred to herein as the transducer unit receiving end of flexure  200 . Platforms  208   a ,  208   b  are also referred to as paddle portions. Stiffeners  212  and  214  are laminated, via adhesive as previously described, onto the tops of conductors  202  and  204  on opposite sides of gap  213  which defines a hinge region. The stiffeners rigidify portions of conductors  202  and  204  outside of hinge region  213 . Additionally, the stiffeners&#39; continuity from side-to-side provides structural compliance between the two load-bearing conductors  202  and  204 . In gimbal region  218  toward the distal end of stiffener  214 , two additional stiffeners  220  and  222  are laminated above the gimbal region  206  of conductors  202  and  204 . Stiffeners  220  and  222  serve to coordinate corresponding conductor regions and to isolate mechanical articulating conductors, i.e., conductive torsional beams, which will be shown and discussed in more detail below.  
         [0140]    [0140]FIG. 14 shows a magnified top view of gimbal region  206  of conductors  202  and  204 . Conductors  202  and  204  are distinctively shaded to assist the viewer in understanding the mechanical relationship and electrical isolation of the conductors. Platforms  208   a  and  208   b  are coordinated and jointly stiffened on the top side by stiffener  222 . On the bottom side of platforms  208   a  and  208   b , transducer chip  210  is attached. It is apparent that platforms  208   a  and  208   b  also function as electrically distinct leads to transducer  210 . Torsional beams (articulators, units, elements)  230   a  and  230   b  allow platforms  208   a  and  208   b  a limited range of pitch flexibility. Similarly, torsional beams (articulators, units, elements)  232   a  and  232   b  allow platforms  208   a  and  208   b  a limited range of roll flexibility. Beams  230   a ,  230   b ,  232   a ,  232   b , collectively, constitute articulator structure which is referred to herein as being characterized by mechanical and electrical homogeneity—i.e., merged functionality. The gimbaling motion permitted by the torsional beams makes possible accommodation of angular or topographic irregularities on the surface of a rigid medium. Although the surface of a medium is ideally flat, in reality, irregularities due to, for example, micro-roughness, polishing/texturing scratches, disk waviness and/or “cupping”, non-parallelism of the spindle and actuator axes, and non-squareness of either of these axes and the disk surface, are inherently present to some degree. The torsional beams also permit the head/flexure to accommodate static mounting tolerances.  
         [0141]    [0141]FIG. 15A shows a top view of the flexure shown in FIG. 13, after assembly. In FIG. 15A portions of conductors  202  and  204  can be seen in hinge region  244  and through window  242  which allows electrical bonding through the top side of flexure  200 . Stiffener  212  also has hole  240  concentrically located above conductor hole  241 . Holes  240  and  241  are used for positioning the suspension on a mounting surface. Near the distal end of flexure  200 , gaps between stiffeners  220  and  222  define flexible torsional beam portions of conductors  202  and  204 .  
         [0142]    An important feature of all the gimbaled flexures described in this application is the configuration of pads (the three contact pads) located on the bottom side of the transducer chip for contacting the surface of the recording medium during read/write operation. Unlike the non-gimbaled flexures, a fundamental objective in the gimbaled designs is to maintain a parallel relationship (zero-angle-of-attack) between the plane of the transducer chip and the surface of the recording medium. For this purpose, a load force is applied, via the deflected flexure, urging the transducer chip into load-bearing contact with the disk&#39;s surface. Multiple pad contact points on the bottom of the transducer chip define a plane of interfacial contact between the chip and the disk. Ideally, torsional beams and/or hinges, load buttons, etc. permit the interfacial contact plane between the disk and the pads to remain intact, despite mounting tolerances and disk surface aberrations, throughout normal read/write system operation. The most common pad configuration employed in the gimbaling flexures of the present invention, consists of a triangular arrangement of three pads, one located in the center of the trailing (or distal) edge of the transducer chip, and the other two pads being located at opposite front corners of the chip. The pole, which is contained typically in the trailing pad, is preferably in constant contact with the surface of the media for the most high-level read/write performance. While this is a typical arrangement, a reverse kind of arrangement is possible, and may offer certain performance advantages in selected applications. More particularly, the central, pole-containing pad could be located adjacent the leading edge of the chip. With this type of arrangement, relative motion between the chip and disk tends to drive the leading-edge pole-containing pad into even more intimate working confrontation to the recording surface in a medium. Further, it is possible that pole structures might be provided in two, or in all three, of the pads.  
         [0143]    Maximum stability is achieved when the pads are located as far apart as possible, consistent with chip size and disk flatness constraints. During pad-disk contact, the pads may be perturbed in the Z direction by hitting pits or asperities in the surface. When this occurs, the downward load must be great enough to restore contact quickly between the pads and the disk. Pad size and shape is not critical except that it is desirable to have the pad that contains the pole be as small as possible to minimize spacing loss, inasmuch as the actual contact point on the pad varies due to disk waviness. For wear reasons, it may be desirable to have larger pads which can sustain larger removed wear volumes. Pads that become too large may create an air-bearing surface that causes a contact-intended transducer to fly rather than to slide. In addition, larger pads may exhibit higher adhesion forces, and consequently additional friction and stiction during operation. Round pads may be desirable so that debris will not collect on a flat leading edge, as has been observed in some cases on square or rectangular pads.  
         [0144]    [0144]FIGS. 15B and 15C illustrate the pad configuration used on the bottom side of transducer chip  210 . Stiffener  214  is laminated, via adhesive  247 , to conductor  202 . Conductor  202  is electrically and mechanically attached to the top side of transducer chip  210  by load-bearing solder structures  248   a  and  248   b . The chip may also be attached to the conductors by processes employing brazing or conductive epoxy materials. As shown in FIG. 15C, pads  250   a ,  250   b  and  250   c  are arranged in a maximally separated triangular configuration on the bottom side of transducer chip  210 .  
         [0145]    A large number of possible pad configurations may be employed in the gimbal structures of the present invention. It is generally preferred to use not more than three pads because four or more contact points create the possibility for rocking of the chip on the disk surface. It is possible for all three pads to be directly connected to the transducer chip, or alternatively, as described in detail below, one or more of the pads may be located on other parts of the flexure which articulate relative to the transducer-carrying portion of the flexure. In most of the gimbal structures described in this application, the pole-containing pad is located on the trailing edge of the chip body. However, as shown by the arrow in FIG. 15C, and as was mentioned earlier, it is possible, and sometimes preferable, to position the pole-containing pad on the leading edge of the chip (by rotating the chip 180°, or by reversing the direction of disk rotation). We have discovered that the pad(s) which is positioned on the leading edge of the chip experiences a significant amount of friction with the disk surface, causing an unloading affect on the pad or pads located on the trailing edge of the chip. This phenomenon must be taken into account when deciding where to position pitch articulators in a gimbal. Further, we have found that electromagnetic signal performance can vary significantly depending on whether the pole-containing pad is on the leading edge or on the trailing edge of the chip body. In general, we have observed a significant increase in signal magnitude when the pole is positioned on the leading edge (instead of on the trailing edge) of the chip.  
         [0146]    In a tri-pad arrangement of the type shown in FIG. 15C, where the transducer chip is mounted on a gimbal permitting all three pads to contact the surface of the medium continuously during normal operation, the transducer chip remains in a substantially parallel orientation, i.e., at a zero-angle-of-attack, relative to the surface of a disk. This feature of the disclosed gimbal structures, represents a major departure from prior transducers/flexures which exhibit substantial angles-of-attack relative to a disk&#39;s surface. Positioning the transducer chip to operate at a zero-angle-of-attack relative to the disk surface provides the capability of employing a transducer design which, due to a particular coil structure, requires the main pole structure to be located inward from the transducer chip&#39;s trailing edge.  
         [0147]    For example, as illustrated in FIGS. 15D and 15E, it is sometimes desirable to locate a pad containing the main pole, inward from the trailing edge of the chip. Flexure/transducer  251  is supported by beam  252 . Transducer chip, or chip body,  253 , which is generally quite thin and planar, is mounted on the bottom side of beam  252 . Projecting tri-pads  254   a ,  254   b  and  254   c  are located on the bottom side of body  253 , defining a plane of interfacial contact between the transducer and the disk&#39;s surface  256 . Inductively coupled to the pole structure is a generally planarly distributed coil, or coil structure, which lies in the plane of chip body  253  in a coil region  255  generally designated by dashed lines in body  253 . As shown, it is sometimes desirable to employ a coil design which extends forward and backward from pole  254   a  along the Y axis. In such a design, it is necessary to position the pole-containing pad inward from the trailing edge of the chip. This design goal is problematic, i.e., sometimes impossible, in a flexure/transducer which positions the chip with a significant angle-of-attack relative to a disk&#39;s surface. This is because, as the pole is moved inward from the trailing edge of a chip body, which is oriented with a significant angle-of-attack, it becomes impossible for the pole to contact the disk. The distance between the pole and the disk becomes greater and greater as the distance between the pole and the trailing edge increases. Accordingly, the flexibility for implementing alternative pole and coil designs in transducers which operate at a significant angle-of-attack is quite limited. It is important to note that the positioning of pitch and roll articulators in a given gimbal configuration is primarily determined by the locations of the contact pads. For example, as the pole-containing pad is moved inward from the trailing edge of the chip body, pitch articulators in the gimbal must also be moved in the same direction in order to maintain the desired gimbal performance and load allocation among the pads.  
         [0148]    In contrast, by providing a flexure/gimbal structure, which is capable of supporting a transducer chip in parallel orientation (zero-angle-of-attack) relative to a disk&#39;s surface, a great improvement in transducer design flexibility is made possible. In the flexure/gimbal structures of the present invention, the pole-containing pad may be located practically anywhere on the working side or surface of the chip without altering the operable spacing (or contact relationship) between the pole and the disk surface. The entire planar body of the transducer chip is available for containing coupled pole structure and coil structure.  
         [0149]    [0149]FIG. 16 is a thin-layer section including the pitch-accommodating torsional beams of the flexure shown in FIG. 15. The structures of torsional beams  230   a  and  230   b  are analogous to conductor hinge  89  in FIG. 6.  
         [0150]    [0150]FIGS. 17A and 17B illustrate a portion of a conductor gimbaling flexure which in all respects is the same as the flexure shown in FIGS.  13 - 16 , except that an additional damping layer is added. In FIG. 17A, damping layer  260  covers substantially the entire gimbal. Damping layer  260  may be, for example, an elastomer available from 3M under the trademark ISD110™ or ISD112™. The material is preferably diluted with ethylacetate to 10% (V/V) of its original concentration, and then applied to the top of the flexure in the gimbal region as shown in FIG. 17A. Use of such a membrane layer results in significant vibrational damping. It is believed that shear energy is absorbed by the membrane, particularly in regions of the gimbal where the maximum amount of vibrational movement is expected to occur. A thin membrane can be employed for this purpose without significantly stiffening the pitch and roll motions otherwise permitted by the gimbal. However, to minimize further any stiffening effect of the membrane on the gimbal, and as is shown in FIG. 17B, a modified damping membrane configuration includes four discrete membranes, or membrane patches,  262   a ,  262   b ,  264   a  and  264   b , each of which bridges two separate conductor portions in an area where the greatest degree of relative movement between the portions is expected to occur. It is preferable to select a damping material which exhibits a relatively high degree of elasticity under static conditions, and a high degree of stiffness when subjected to a high-frequency condition.  
         [0151]    Another desirable way of employing a damping membrane, such as the ones illustrated in FIGS. 17A and 17B, is to position the damping membrane between either stiffener and conductor, or the flexure and an additional constraining layer. Ideally, the adhesive layer, which is already required in each of the laminant flexures described herein, and which can furnish damping action, may extend continuously through the gimbal region. The adhesive layer may extend through all of the gaps between stiffeners  214 ,  220  and  222  in the gimbal region. Alternatively, and in order to minimize any stiffening effect of the membrane on the gimbal, the adhesive layer may bridge gaps between stiffeners only in discrete regions where maximum movement between the stiffeners is expected to occur, similar to the configuration shown in FIG. 17B.  
         [0152]    [0152]FIG. 18 shows another embodiment of a gimbaled transducer/flexure which employs a membrane interconnecting a flexure body and a transducer chip. In the structure shown in FIG. 18, the membrane functions primarily as a gimbaling structure and possibly also a damping layer. Transducer/flexure  270  includes a flexure frame portion  271  from which trace conductors  272   a  and  272   b  extend to transducer chip  273 . Three contact pads  274   a ,  274   b  and  274   c  (dashed lines) are located on the bottom (working) side of transducer chip  273 . The transducer pole (not shown) is preferably located in contact pad  274   a . In this design, trace conductors  272   a  and  272   b  are downsized (compared to previously described conductors) and shaped (folded or curved) so as to make the conductors insignificant structural contributors in the transducer/gimbal region. Elastomeric membrane  276  spans the gap region between flexure frame portion  271  and transducer chip  273 . As already described with reference to FIGS. 17A and 17B, a membrane interconnecting a flexure frame and a transducer chip can be employed advantageously for the purpose of damping vibrations. However, the primary function performed by membrane  276  is to bear the cantilever load while permitting ranges of pitch and roll movement of transducer chip  273 . Membrane layer  276  is the only significant load-bearing connection between frame portion  271  and transducer chip  273 . By selecting the appropriate type, thickness and configuration, membrane  276  may function as a gimbal structure to allow pitch and roll movement of transducer chip  273  independent from flexure frame portion  271 , while possibly also damping vibrations. Membrane  276  is preferably sandwiched between flexure frame subportions and/or conductors.  
         [0153]    [0153]FIGS. 19A, 19B and  20  illustrate a flexure which is similar to the one illustrated in FIGS.  13 - 16  except for several important differences. As shown in FIG. 19A, flexure  280  has two hinges  281  and  282 . Hinge  281  is characterized by a cut-out window in stiffener  283  near its proximal end exposing relatively thin conductors  284  and  286 . The outlines of conductors  284  and  286  underneath the stiffeners are shown in dashed lines. It is apparent that, although the reduced dimensions of conductors  284  and  286  in the proximal hinge region (relative to the dimensions of previously described conductors) diminishes the load-bearing function of the conductors in that region, in the intermediate region of the flexure the conductors are wider, and therefore carry a significant portion of the load. The configuration of modified hinge  280  results in a higher spring constant for accommodating higher loads in comparison to the loads carried by previously described flexures.  
         [0154]    The configuration of hinge  282  near the distal end of the flexure is similar to previously described hinges in that conductors  284  and  286  are the sole load-bearing structures in that region. Gimbal  288  allows pitch and roll movement of stiffened transducer-carrying platform  289 . Similar to the gimbal shown in FIGS.  13 - 15 , gimbal  288  employs torsional beams  290   a  and  290   b  to allow roll movement of platform  289  independent from the body of flexure  280 . Pitch movement is facilitated by hinges (articulators, units, elements)  292   a  and  292   b  which are rearwardly displaced from the center of the platform in order to equalize load distribution among the three medium-contacting pads (not shown). The use of hinges instead of torsional beams provides the important advantage of increased longitudinal and yaw stiffness. Another advantage of using hinges to provide pitch movement instead of torsional beams is that overall width of the flexure in the gimbal region can be reduced. The pitch-permissive hinges also provide a platform for dispensing adhesive. The configuration of conductors  284  and  286  in gimbal region  288  of flexure  280  is shown in FIG. 19B. Conductor  286  enters the gimbal mechanism through roll-permissive torsional beam  290   a , and enters the transducer-carrying region through pitch-permissive conductor/hinge  292   a  to end in transducer-carrying semi-platform  293   a . Similarly, conductor  284  enters the gimbal mechanism through roll-permissive torsional beam  290   b , and enters the transducer-carrying region through pitch-permissive conductor hinge  292   b  to end in transducer-carrying semi-platform  293   b.    
         [0155]    [0155]FIG. 20 shows a side view of flexure  280  operating on disk  295 . Most of the bending which results from deflection of the flexure occurs in hinges  281  and  282 . Gimbal  288  mounts and supports transducer chip  296 . A “tri-pad” configuration (only two pads  297   a  and  297   b  are shown), as previously described, exists for maintaining an interfacial contact plane between chip  296  and the surface of disk  295 .  
         [0156]    Flexure  300 , as shown in FIG. 21, is the same as flexure  280  shown in FIG. 19, except that the dimensions of conductors  302  and  304  in region I are modified, and that flexure  300  is pre-bent in proximal hinge region  306  (FIG. 22A). This prebend exists along an axis  306   a  (see FIG. 21) which defines a preferential bending axis for flexure  360 .  
         [0157]    Stiffener layers  301   a ,  301   b ,  301   c  and  301   d  are laminated on top of conductors  302  and  304 . The lateral dimensions of conductors  302  and  304  in region I are shown in dashed lines because the conductors are covered by stiffener  301   a . The reduction of conductor width in region I can result in a significant reduction in capacitance levels.  
         [0158]    The conductors can be made of different materials. However, a number of factors must be considered when selecting an appropriate conductor material. In addition to being able to conduct electricity, the conductor material must exhibit appropriate physical/mechanical properties within the geometric and dimensional limitations which dictate the operation and overall size of the flexure. When the conductors function as the only load-bearing components of the proximal hinge, as in previously described designs, it is preferable to use materials, such as stainless steel, which have a relatively high elastic (Young&#39;s) modulus resulting in higher modal frequencies, and high tensible strength which can therefore support higher loads. However, in flexures such as the ones shown in FIGS.  19 - 22 B, where the conductors are relatively insignificant load-bearing components in the proximal hinge, beryllium copper is a suitable choice of material. With some conductor materials, such as stainless steel, it is preferable to gold-plate the entire surface for at least two reasons. First, gold-plating in the bonding regions facilitates a solder connection. Second, gold-plating the entire stainless steel beam reduces resistance. When beryllium copper is used as the conductor material, it is only necessary to gold-plate the bonding regions.  
         [0159]    [0159]FIG. 22A shows flexure  300  in its unloaded position U (solid lines) and in its loaded position L (dash-dot lines) relative to disk  310 . By pre-bending flexure  300  in hinge region  306  (on axis  306   a ), flexure mount  312  can be parallel to the disk surface, thereby, minimizing disk-to-disk spacing.  
         [0160]    [0160]FIG. 22B illustrates a modification of flexure  300  which involves the use of gimbal-motion-limiting guides, or “bumpers”, for the purpose of avoiding extreme, potentially catastrophic movement of gimbal parts out of the plane of flexure  300  in the case of a relatively high-shock situation. Read/write systems are sometimes subjected to high-shock forces, for example, when a system is dropped or moved abruptly. In this situation, gimbal parts which are connected by relatively small hinges or torsional beams, may be moved, bent or broken permanently away from their operable positions. Accordingly, the modification of flexure  300  shown in FIG. 22B, provides motion-limiting bumpers for preventing extreme movement of the gimbal parts with respect to the flexure body and to each other. In FIG. 22B, flexure  300  includes conductors  302  and  304 , the configuration of which has already been discussed referring to FIGS. 19A through 22A. Stiffeners  312   a ,  312   b ,  312   c  and  312   d  are laminated on top of conductors  302  and  304 . Stiffeners  312   b ,  312   c  and  312   d  differ from previously described stiffeners in that they include tabs which extend over air gaps between gimbal parts. These tabs partially cover (but do not touch) exposed conductor regions in an adjacent gimbal part. For example, tabs  314   a ,  314   b ,  314   c  and  314   d  extend over conductor edge regions of gimbal part  317 . Bumpers  314   a ,  314   b ,  314   c  and  314   d  significantly limit the extent to which gimbal part  317  can move above the plane of flexure  300  in a high-shock situation, while still allowing the desired range of roll torsional movement of the transducer chip independent from the body of flexure  300 . Similarly, tabs  316   a  and  316   b  are extensions of stiffener  312   c , protruding over conductor edge regions of transducer-carrying platform  318 . Bumpers, or tabs,  316   a  and  316   b  prevent extreme movement of platform  318  above the plane of gimbal part  317  or the body of flexure  300 , while still allowing the desired degree of pitch movement of platform  318  independent from the rest of flexure  300 . Extreme movement of the gimbal parts below the body of flexure  300 , can also be prevented by outwardly extending tabs  319   a ,  319   b ,  319   c  and  319   d . Each of tabs  319   a ,  319   b ,  319   c    319   d  extend over a gap separating gimbal part  317  from the body of flexure  300 , and over an exposed conductor region defined by corresponding cut-outs in stiffener  312   b . It is apparent (although not shown) that similar outwardly extending tabs could be employed to limit extreme movement of platform  318  below the plane of gimbal part  317 .  
         [0161]    FIGS.  23 - 25  illustrate modified conductor gimbal configurations employing conducting articulators, namely, torsional beams, to allow limited ranges of pitch and roll movement of a transducer platform independent from a flexure body. Each of the gimbaling conductor structures shown in FIGS.  23 - 25  can be implemented, with corresponding stiffeners, in flexures such as the ones shown in FIGS.  13 - 22 B. Specifically, the gimbaling conductor structure shown in FIG. 14 could be replaced (along with appropriately modified stiffeners) with any one of the structures shown in FIGS.  23 - 25 .  
         [0162]    In FIG. 23, gimbaling conductor configuration  320  is similar to the one shown in FIG. 14, except that pitch-permissive torsional beams  322   a  and  322   b  are located laterally and externally from roll-permissive torsional beams  324   a  and  324   b . In contrast to the FIG. 14 configuration, where pitch-permissive torsional beams  230   a  and  230   b  connect directly to transducer-carrying platforms  208   a  and  208   b , in the FIG. 23 configuration, roll-permissive torsional beams  324   a  and  324   b  connect directly to transducer-carrying platforms  325   a  and  325   b.    
         [0163]    [0163]FIG. 24 illustrates the point that gimbaling conductor configurations may employ torsional beams which are obliquely angled relative to lengthwise axis AX of the flexure. In gimbaling conductor configuration  330 , the axes of external torsional beams  332   a  and  332   b , and internal torsional beams  334   a  and  334   b  are each obliquely angled relative to axis AX. The FIG. 24 configuration also illustrates the point that the torsional axes of torsional beam pairs, i.e.,  332   a  and  332   b  versus  334   a  and  334   b , do not need to be perpendicular to each other. These beams perform as mixed-mode articulators, with both hinging and torsional action.  
         [0164]    In FIG. 25, the gimbaling conductor configuration is similar to the FIG. 14 configuration, except for the addition of longitudinal stiffening arms  342   a  and  342   b , each of which may be described as a simply supported cantilever with applied moment. Ideally, arms  342   a  and  342   b  should connect with  344   a  and  344   b , respectively, as close to the center of the gimbal as possible.  
         [0165]    All of the gimbaling conductor configurations mentioned so far, embody a single pair of conductors. In contrast, FIG. 26 illustrates a gimbaling conductor configuration with four conductors  352 ,  354 ,  356  and  358 . These form conductors are differently shaded in order to illustrate and clarify their respective paths from the flexure body into and through the gimbal. Each of conductors  352 ,  354 ,  356  and  358  contributes two torsional beams and one quadrant of a transducer-carrying platform. For example, conductor  352  runs through torsional beam  352   a , then through torsional beam  352   b  and ends in transducer-carrying platform quadrant  352   c . Each of the other conductors follows a similar complementary path.  
         [0166]    [0166]FIG. 26 also illustrates that the four right-angle torsional beams shown in the FIG. 14 configuration can be replaced with four pairs of beams, wherein each pair includes two oblique beams. Each pair of oblique beams, for example, the pair including beams  360  and  352   a , is referred to as a “triangular, dual-beam torsional articulator”. The triangular dual-beam torsional articulator provides greater stiffness in comparison to the single right-angle beam systems previously described. It is also possible to produce a gimbaling conductor configuration in which torsional beams  360  and  352   a  are parallel to each other.  
         [0167]    The gimbaling conductor structure shown in FIG. 27A is fundamentally different from the previously described gimbals because, here, gimbaling movement is facilitated by hinges instead of by torsional beams. In FIG. 27A, flexure  380  includes conductors  382  and  384 . Moving toward the distal ends of conductors  382  and  384 , roll-permissive gimbal regions  386  and  388  are defined. Nearer the distal ends, pitch-permissive hinge regions  390  and  392  are defined. FIG. 27B illustrates the distal end region of flexure  395  which includes the gimbaling conductor structure  380  of FIG. 27A, with the addition of top stiffening layers  394 ,  396  and  398 . Stiffeners  394 ,  396  and  398  stiffen all areas of the conductors except for isolated hinge regions  386 ,  388 ,  390  and  392 .  
         [0168]    This hinging gimbal configuration provides several important advantages. First, it can be made smaller (less width required) compared to the gimbal configurations which employ torsional beams, and this allows more of the disk surface, at the inner diameter, to be used for recording data since less pole-to-hub clearance is required. Second, a considerable amount of design flexibility is achieved with roll-permissive hinges  386  and  388  which can be positioned practically anywhere along the length of the flexure.  
         [0169]    FIGS.  28 A- 30  illustrate another type of flexure which includes what may be thought of as a gimbal, but which differs from previous embodiments principally in that roll flexibility is achieved by the flexure body itself (i.e., by a “torsionally compliant beam”) rather than by torsional beams or hinges, as in previously described gimbals. Three torsionally compliant beams are illustrated. In FIGS. 28A and 28B, a torsionally compliant beam without a pitch gimbaling mechanism, is illustrated. In FIGS. 29A and 29B, a torsionally compliant beam is equipped with pitch-permissive torsional beams in the distal end of the flexure. In FIG. 30, a torsionally compliant beam with pitch-permissive hinges, is shown.  
         [0170]    The first torsionally compliant beam, or flexure, described is shown in FIGS. 28A and 28B. Torsionally compliant flexure  400 , from top view, includes three principal portions, namely, base portion  401 , neck portion (also referred to as a “torsional compliance portion”)  402  and head portion  403 . In a preferred embodiment, base portion  401  has a width W1 of 60-mils. Neck portion  402  has a width W2 of 20-mils. Head portion  403  has a width W3 of 40-mils. Conductors  404   a  and  404   b  (dashed lines in FIG. 28A) are adhesively bonded to overlying stiffeners  405   a  and  405   b . A hinge region  406  is defined by internal edges of stiffeners of  405   a  and  405   b . Three contact pads  407   a ,  407   b  and  407   c  are linearly arranged along the trailing edge of transducer chip  408  which is bonded via solder structures  409   a  and  409   b  to the bottom sides of conductors  404   a  and  404   b . Centrally located contact pad  407   b  contains the transducer pole. Only two of the three pads are necessary for the flexure to exhibit torsional compliance. For example, the central pad could be eliminated and the pole could be located in either one of the pads  407   a  and  407   c . If the pole is located in one of the off-center pads, it is preferable for the pole to be located in the outside pad, i.e., the side of the chip which is closest to the outer perimeter of the disk, in order to maximize the amount of usable space on the disk. Alternatively, a pole can be located in each of the contact pads  407   a  and  407   c . The two poles can be used alternately or selectively depending upon the particular situation. Flexure/transducer  400  is shown with two conductors. However, it is apparent that a similar torsionally compliant flexure design employing four or more conductors can be easily designed and fabricated.  
         [0171]    A torsionally compliant beam must include the following interrelated features: (1) the neck portion of the beam must be sufficiently torsionally soft to permit a desired range of roll movement of the head portion while maintaining sufficient lateral rigidity; (2) there must be at least two laterally-spaced contact pad points underneath the head portion of the flexure; (3) there must be sufficient load applied to the head portion so that a line of interfacial contact between the contact pad points and the surface of the disk is maintained despite external irregularities or aberrations which cause torsional flexing of the neck portion of the beam; and (4) the beam must exhibit sufficient lateral (anti-yaw) stability. Generally, as the distance between the laterally spaced contact points increases, less load is required in order to permit a desired degree of roll movement. Preferably, a torsionally compliant beam is sufficiently soft to permit plus or minus about 0.2° of roll under a total contact load of 300-mg. or less.  
         [0172]    Note that flexure  400  is a gimbaling beam only in the sense that it permits roll motion of the transducer chip. Flexure  400  does not include any pitch gimbaling mechanism. The torsionally compliant beams illustrated in FIGS.  29 A- 30  are similar to flexure  400 , except they additionally include pitch gimbaling mechanisms.  
         [0173]    The second torsionally compliant beam illustrated is shown in FIGS. 29A and 29B. Flexure  410  includes load-bearing conductors  412  and  414  which are separated from each other and extend the entire length of the flexure body. Importantly, the distal ends of conductors  412  and  414  are configured cooperatively to provide pitch gimbaling. Parallel distal central regions  418   a  and  418   b  of conductors  412  and  414  form, collectively, a platform  418  for mounting transducer chip  419 . Stiffeners  420 ,  422  and  424  are laminated by adhesive (not shown), to the top sides of conductors  412  and  414 . Stiffener  424 , laminated to the top side of platform  418 , leaves exposed torsional beams  430   a  and  430   b  which allow a selected range of pitch gimbaling of transducer chip  419 . A triangular configuration of pads is employed on the working side of transducer chip  419 . One pad is located near the center of the trailing edge of chip  419 . The other two pads are located at opposite rear corners of the leading edge of the chip. Similar to previously described gimbal designs, the three pad configuration defines an interfacial contact plane between the transducer chip and the surface of the recording medium.  
         [0174]    Importantly, for a given selected material, intermediate neck portion  432  of flexure  410  is dimensioned (width, length and thickness) relative to the distance between laterally spaced contact pads on the bottom side of transducer chip  419 , and the amount of load applied to chip  419 , so that the neck portion is sufficiently torsionally soft to allow a desired range of roll movement of the transducer-carrying platform, while maintaining the plane of interfacial contact between the contact pads and the disk surface so that a desired range of torsional flexibility (typically 0.2° to 2.0°) for the transducer-carrying platform is permitted. Ideally, the beam is sufficiently torsionally soft to allow the transducer chip to roll approximately plus or minus one degree from applied moment due to the load. For example, flexure  410  has the following specifications: the load is approximately 300- to 350-milligrams; the width of the neck portion  432  of the beam is approximately 20-mils.; the length of the beam from proximal hinge to its distal tip is approximately 350-mils.; and the transducer chip  419  is 40-mils. by 40-mils.  
         [0175]    The flexure  440 , shown in FIG. 30, is essentially the same as torsionally compliant beam  410 , except that a pitch gimbaling movement is permitted by hinges  442  and  444  instead of by torsional beams.  
         [0176]    FIGS.  31 - 34 C illustrate another set of embodiments of the invention, referred to as “dual-cantilever” flexures. In these embodiments, also referred to as disk read/write structures, beams are stacked and spaced from each other by spacers located at each end. The overall dual-cantilever configuration may be referred to as a “parallelogram articulation substructure”. Analogous to a “four-bar linkage”, the flexure can be flexed without significantly altering the angular relationship between the transducer mounted on the distal end and the surface of a recording medium. Dual-cantilever flexure  460 , as illustrated in FIG. 31, has two sets of conductors and four hinges. However, the dual-cantilever concept could also be implemented in a flexure with one pair of conductors and/or no hinges. Flexure  460  includes a top layer of side-by-side spaced conductors  462  and  464  which are laminated by adhesive, as previously described, to stiffeners  466 ,  468  and  469 , with gaps  470   a  and  471   a  defining proximal and distal hinge regions, respectively. Stiffeners  466  and  469  are mounted on top of spacers  472  and  474 , which in turn are mounted on top of stiffeners  476  and  477  on opposite sides of stiffener  478 . Stiffener  476  is separated from stiffener  478  by a gap  470   b  which defines a second proximal hinge region in addition to  470   a . Similarly, stiffener  478  and  477  are separated by a gap  471   b  which defines a second distal hinge region in addition to  471   a . Stiffeners  476 ,  477  and  478  are laminated on top of conductors  480  and  482 . The distal ends of conductors  480  and  482  support and are mounted on top of transducer chip  484 . FIG. 32 shows a perspective view of flexure  460 , assembled.  
         [0177]    [0177]FIG. 33 shows the unloaded U (solid lines) and loaded L (dash-dot lines) positions of flexure  460  relative to disk  490 . Note that flexure  460  is pre-bent in its unloaded position, with most (ideally all) of the bending occurring in hinge regions  470  and  471 . A notable feature of the dual-cantilever design is that equal and opposite bending occurs toward opposite ends of the flexure. Accordingly, as shown in FIG. 33, pre-bends in proximal hinge regions  470   a  and  470   b  are oppositely matched by pre-bends in distal hinge regions  471   a  and  471   b , respectively, so that transducer chip  484  maintains a parallel relationship with disk  490  as it moves from its unloaded to its loaded position. As shown in FIG. 33, by pre-bending a dual-cantilever flexure, an extremely close spacing between flexure mount  491  and disk  490  is permitted.  
         [0178]    FIGS.  34 A- 34 C illustrate a modified dual-cantilever flexure which does not have any stiffeners, hinges or pre-bends. Thus, it is apparent that the dual-cantilever concept can be practiced beneficially in an unhinged (and non-pre-bent) flexure because one of the main reasons to use a proximal hinge, i.e., minimization of the angular constant of the distal end, is substantially achieved by the dual-cantilever linkage itself. In FIG. 34A, flexure  500  includes top layer conductors  502  and  504  mounted on top of spacers  506  and  508 , on top of conductors  510  and  512 . It is necessary to provide electrical connection from the top layer conductors, for example,  502  and  504 , to transducer  514  which is mounted on the bottom side of the distal ends of conductors  510  and  512 . FIG. 34B shows a perspective view of flexure  500 , assembled.  
         [0179]    [0179]FIG. 34C shows a side view of flexure  500  in its unloaded U (dash-dot lines) and loaded L (solid lines) positions, relative to disk  518 .  
         [0180]    The dual-cantilever concept can also be embodied in flexure designs with more or less than four conductors. It is also possible to isolate all of the conductors in either of the top and bottom layers. It is sometimes preferable to isolate all of the conductors in the bottom layer because the distal ends of the bottom layer conductors are in better position for electrical connection to the transducer chip. For example, FIG. 35 shows a dual-cantilever transducer/flexure  520  including top beam member  521  spaced from conductors  522   a  and  522   b  by spacers  523   a  and  523   b  located near the proximal and distal ends of the flexure, respectively. Transducer chip  524  is mounted on the bottom sides of the distal ends of conductors  522   a  and  522   b.    
         [0181]    Still another dual-cantilever embodiment  526 , as shown in FIG. 36A, includes two conductors  527   a  and  527   b , each conductor extending continuously over either the top or bottom layer of flexure  526 . Near the proximal end of the beam, conductors  527   a  and  527   b  are separated by spacer  528 . A transducer chip  529   a  is mounted to the distal end of the beam in an “on-end” or vertical orientation. As shown in FIG. 36B, chip  529   a  is bound to conductors  527   a  and  527   b  by conductive epoxy bonds  529   c  and  529   d , thus eliminating the need for an additional spacer at the distal end of the beam. Transducer chip  529  is mounted on the bottom side of the distal end of conductor  527   b.    
         [0182]    [0182]FIG. 37A illustrates a flexure mounting device which contacts and follows the surface of the disk, thereby eliminating the need for a pitch gimbal in the flexure. The device includes mount arm  532  attached to pad  534  which contacts and follows the surface of relatively moving disk  536 . Flexure  538  is attached to mount arm  532 , and supports, at its distal end, transducer chip  540  which contacts the surface of disk  536  via contact pad  542 . Assuming spacer pad  534  maintains contact with disk  536 , the height point  544  where the proximal end of flexure  538  is mounted, is maintained constant. By mounting flexure  538  on a mounting device which follows the contours of the disk, the need for pitch gimbaling is eliminated.  
         [0183]    The transducer/flexure designs illustrated in FIGS. 37B and 37C relate to the mounting structure shown in FIG. 37A in the sense that contact pads are located on separate structures which are allowed a range of articulation movement with respect to each other. Generally, this important feature of the invention makes possible gimbal designs in which the contact pads are spread out further from each other—resulting in greater surface accommodating stability. This is a contrast to the pad configurations previously described in which the distance between the pads has been generally limited by the size of the transducer chip.  
         [0184]    In FIG. 37B, transducer/flexure  545 , near its distal end  546   a , has a hole  546   b  for mounting, and a bonding window  546   c . A proximal hinge region  546   d  exposes conductors  546   e  and  546   f  which are also exposed through bonding window  546   c . Moving toward the distal end of transducer/flexure  545 , in an intermediate region, stiffeners  546   g  and  546   h  are laminated on top of conductors  546   d  and  546   f , respectively. Conductors  546   e  and  546   f  are again exposed in a second hinge region defined by spaces between stiffeners  546   g ,  546   h  and stiffener  546   k . On the bottom side of the flexure portion stiffened by stiffener  546   k , contact pads  546   l  and  546   m  are positioned near opposite lateral edges of the portion. Conductors  546   e  and  546   f  are again exposed in a third hinge region defined by a space between stiffener  546   k  and stiffener  546   p . Underneath and toward the distal end of stiffener  546   p , transducer  546   q  is mounted. A contact pad  546   r  is located on the bottom side of transducer  546   g , near its trailing edge. Transducer/flexure  545  can be viewed as being made up of plural, articulated beam portions.  
         [0185]    In transducer/flexure  545 , the conductors in the second hinge region and laterally spaced contact pads  546   l  and  546   m , collectively provide for gimbaling movement of the transducer chip independent from the proximal end region of the flexure body. Pitch movement of transducer chip  546   q  is made possible by the conductor hinges in the third hinge region between the laterally spaced contact pads and the centrally located pad at the distal tip of the transducer chip.  
         [0186]    The transducer/flexure shown in FIG. 37C is similar to the one shown in FIG. 37B. Transducer/flexure  547 , near its proximal end  548   a , has a hole  548   b  for mounting alignment, and bonding windows  548   c  and  548   d . Conductors  548   e ,  548   f ,  548   g  and  548   h  are exposed in bonding windows  548   c  and  548   d , respectively, and in a first hinge region  549   a . Moving distally along the flexure, stiffener  548   i  is laminated on top of conductors  548   e  and  548   f , and stiffener  548   i  is laminated on top of conductors  548   g  and  548   h . The conductors are again exposed in a second hinge region  549   b  which is defined by the spaces between stiffeners  548   i ,  548   i  and stiffener  548   k . On the bottom side of the flexure region stiffened by stiffener  548   k , are laterally spaced contact pads  5481  and  548   m  (shown in dashed lines). Continuing to move toward the distal end of the flexure, the conductors are again exposed in a third hinge region  549   c , defined by the space between stiffener  548   k  and  548   n . At the distal end of the flexure, transducer chip  548   o  (shown in dashed lines) is mounted on the bottom side of the flexure. A pole containing contact pad  548   p  (shown in dashed lines) is located on the bottom side of transducer chip  548   o.    
         [0187]    Each of the embodiments shown in FIGS.  37 A- 37 C, illustrates important modification options relating to contact pad configurations. First, these embodiments (FIGS.  37 A- 37 C) show that the contact pads do not have to be formed on the chip itself, as they are in the previously described transducer/flexure designs. Second, it is possible to position one or more of the contact pads on beam portions of the flexure which articulate independently from the flexure portion on which the transducer is mounted. For example, in a gimbal such as the one shown in FIGS.  13 - 15 C, the laterally-spaced contact pads on the leading edge of chip  210  could be replaced on the bottom side of the roll frame stiffened by stiffener  220 . These principles make it possible to increase greatly the longitudinal and lateral distances between the pads within constraints due to size and disk waviness. As already noted, increasing the distances between the pads improves the operable stability of the flexure. Increase in the distance between the pads also makes it possible for the gimbal to perform under a lighter load. Minimizing the load, in turn, is important for the purpose of minimizing wear, reducing function, and lowering the probability of head and/or disk crash events.  
         [0188]    FIGS.  38 A- 38 C illustrate two flexure mounting systems. The mounting system illustrated in FIGS. 38B and 38C employ a dual-cantilever structure resulting in closer disk-to-disk spacing in comparison to previous flexure mounting systems, such as the one illustrated in FIG. 38A. The flexure mounting system  550 , shown in FIG. 38A, includes E block  552  supporting flexure mounts  554   a ,  554   b ,  554   c  and  554   d , which in turn hold flexures  556   a ,  556   b ,  556   c  and  556   d , respectively. The flexures are supported in contacting relationship with opposing surfaces of disks  558   a  and  558   b . Because of the relatively rigid relationship between E block  552  and mounts  554   a - 554   d , in order to accommodate mounting and operating tolerances, a relative large spacing distance  560  must be maintained between the disks. In contrast, the flexure mounting system  570 , as shown in FIG. 38B, permits significantly closer disk-to-disk spacing, by using a dual-cantilever in the mounting structure. In flexure mounting system  570 , E block  572  supports dual-cantilever mounting structure  574  which has an elongate distal end  576  connected to flexure  578 , which end supports transducer chip  580  in contact with the surface of disk  582 . Each of the other flexures in the system shown in FIG. 38B, is similarly mounted. Dual-cantilever structure  574  allows relative movement between E block  572  and disk  582 , while maintaining a parallel relationship between its elongate distal end  576  and the surface of disk  582 . Accordingly, requisite disk-to-disk spacing  584  is greatly reduced relative to disk-to-disk space  560  in the prior system illustrated in FIG. 38A.  
         [0189]    [0189]FIG. 38C is a magnified view of a single flexure mounting device from FIG. 38B. The elongate distal end  576  of dual-cantilever structure  574  supports pad  586  in a contacting relationship with the surface of disk  582 . The proximal end of flexure  578  is attached to dual-cantilever structure distal end  576 . By employing dual-cantilever structure  574  and disk-contacting pad  586 , dual-cantilever distal end  576  is maintained in a parallel relationship to the surface of disk  582 , and at a constant height above the disk. In addition to allowing closer disk-to-disk spacing, the design shown in FIG. 38C also substantially eliminates the need for pitch gimbaling analogous to the system illustrated in FIG. 37A.  
         [0190]    Another aspect of the present invention relates to the goal of simplifying the process of mounting a flexure on an E block, and more specifically, providing an easy way of connecting the flexure electrically to a flex cable. FIGS.  39 A- 39 C illustrate a flexure mounting structure which is versatile in the sense that it can be easily electrically connected to a mother flex cable in either an upside or a downside orientation. Nut-plate/flexure structure  587   a , as shown in FIG. 39A, includes a flexure  588   a  which may take the form of any of the flexures previously described in this application, except for its different conductor structure. Nut-plate  588   b  is welded by spots  588   c  to a stiffener layer which is laminated on top of conductors  589   a  and  589   b  toward the proximal end of flexure  588   a . Conductors  589   a  and  589   b  run from the transducer chip through the flexure where conductor  589   a  passes through the center region of the flexure and conductor  589   b  extends along both sides of the intermediate portion of flexure  588   a . Conductor  589   b  then passes under nut-plate  588   b , and eventually extends in opposite lateral directions along paths leading to laterally opposite, proximally located tabs  588   aa  and  588   bb . Similarly, centrally extending conductor  589   a  extends under nut-plate  588   b  and eventually splits into separate laterally opposite directions on paths which-end in tabs  588   aa  and  588   bb . On tab  588   aa  conductors  589   a  and  589   b  are exposed on the bottom side, and therefore are not visible in the view shown (dashed lines). Conversely, conductors  589   a  and  589   b  are exposed on the top side of tab  588   bb . Thus, if nut-plate/flexure  587   a  is mounted under an E block arm, electrical connection to the flex cable is accomplished by bending tab  588   bb  up so that the conductors contact the flex cable conductors. Alternatively, if nut-plate/flexure  587   a  is mounted on top of an E block arm, electrical connection is accomplished by bending tab  588   aa  down so that conductors  589   a  and  589   b  contact the conductors in the flex cable. FIG. 39B shows four nut-plate/flexures, each one configured as shown in FIG. 39A, mounted on an E block. Nut-plate/flexure  587   a  is electrically connected to a flex cable  588   d  via conductor contact tab  589   bb . Nut-plate/flexure  587   b  is electrically connected to flex cable  588   d  through conductor contact tab  589   cc . Nut-plate/flexure  587   c  is electrically connected to flex cable  588   d  through conductor contact tab  589   dd . Nut-plate/flexure  587   d  is electrically connected to flex cable  588   d  through conductor contact tab  589   ee.    
         [0191]    [0191]FIG. 39C shows a modified conductor configuration that results in lateral tabs which facilitate easy upside/downside electrical connection to a flex cable. Nut-plate/flexure  588   e  includes conductors  589   i  and  589   i  which extend from a gimbaled transducer mounted near the distal end of the flexure, through the flexure body, under the nut-plate, into semi-circular conductor contact tab  589   ff  then to conductor contact pad  589   gg . On tab  589   ff , conductors  589   i  and  589   j  are upwardly exposed. On pad  589   gg , conductors  589   i  and  589   i  are downwardly exposed, and therefore not visible in the view shown (dashed lines).  
         [0192]    The flexures previously described are generally designed to operate under a load in the range of 30- to 300-, and preferably 35- to 70-milligrams. It is important to minimize the load exerted on the flexure during operation in order to minimize the rates of head and disk wear and to lower frictional power consumption. However, for those flexures which include a gimbal, it is necessary to apply a load which is great enough to maintain contact between the transducer chip contact pads and the disk surface, through the desired ranges of pitch and roll movement. It is generally possible to upsize and downsize the flexure designs described in this application, for use under different applied loads. For example, the load which is required for adequate gimbaling of a given flexure design, can be decreased by lengthening and/or thinning the dimensions of gimbal articulator structures, i.e., hinges or torsional beams.  
         [0193]    FIGS.  40 A- 40 C illustrate a flexure which is designed to operate under a load of approximately 35- to 70-milligrams. Beginning near the proximal end of flexure  590 , a hole  591   a  is provided for mounting alignment. A window  591   b  exposes conductors  592   a  and  592   b  for electrical bonding. Within proximal hinge region  591   c , conductors  592   a  and  592   b  are again visible. The primary structural components of hinge region  591   c  are stiffener straps  591   d  and  591   e  which are integral parts of stiffener  591   f . Approaching the distal end of flexure  590 , distal hinge region  591   g  is made up of lateral edge portions of conductors  592   a  and  592   b . A gimbal  591   h  is provided near the distal end of flexure  590  for mounting a transducer and for facilitating movement of the transducer independent from the main body of flexure  590 . Three separate stiffeners  591   i ,  591   j  and  591   k  define gimbal articulators which are shown in more detail in FIGS. 40B and 40C. Dimensions of flexure  590  are as follows:  
         [0194]    AA=0.060-inches  
         [0195]    BB=0.455-inches  
         [0196]    CC=0.030-inches  
         [0197]    DD=0.010-inches  
         [0198]    EE=0.350-inches  
         [0199]    FF=0.080-inches  
         [0200]    [0200]FIG. 40B illustrates an isolated top view of the conductors  592   a  and  592   b . The conductors are separately shaded in order to emphasize their separate paths. Stiffening layers  592   c  and  592   d  are co-planar with conductors  592   a  and  592   b , but are separate from the conductors so they do not function as conductors in flexure  590 . Conductor  592   a  extends to the distal tip of flexure  590 , then passes toward the transducer chip through torsional beam  592   e , then through hinge  592   f , finally ending in a transducer mounting platform  592   g . Similarly, conductor  592   b  passes through torsional beam  592   h , then through hinge  592   i , and ends in a transducer mounting platform  592   j.    
         [0201]    [0201]FIG. 40C shows a magnified view of the assembled gimbal in flexure  590 . As previously described, stiffeners  591   i ,  591   i  and  591   k  expose and define gimbal articulators, namely, roll-permissive torsional beams  592   e  and  592   h , and pitch-permissive hinges  592   f  and  592   i . Shock-resistant tabs  594   a ,  594   b ,  594   c  and  594   d  extend across the gap between stiffeners  591   i  and  591   k . These tabs limit the distance or extent to which the transducer-carrying central region of the gimbal can move upward along the Z axis out of the plane containing the roll structure stiffened by stiffener  591   j . Similarly, tabs  595   a ,  595   b ,  595   c  and  595   d  extend across the gap between stiffeners  591   i  and  591   j , thereby limiting the extent to which the roll frame can move upward along the Z axis above the plane containing the main body of the flexure. The primary purpose of the tabs is to limit the movement of gimbal parts in a high-shock situation.  
         [0202]    Miniature reservoirs for containing dampening material in and around the gimbal region are also defined. Each reservoir is typically formed by making semi-circular cuts on opposite edges of stiffeners near a gap between gimbal parts. For example, an outer organization of reservoirs  597   a ,  597   b ,  597   c  and  597   d  facilitate deposition of a damping material through a syringe, for example, damping material  598  in reservoir  597   a , creating a bridge across the gap between stiffener  591   i  and  591   j . Two more damping material reservoirs  599   a  and  599   b  are located across gaps between stiffeners  591   j  and  591   k  on opposite sides of stiffener  591   k . Hole  599   c  in the center of stiffener  591   k  is provided to permit application of adhesive for the purpose of bonding the chip to the suspension. Preferred dimensions in the gimbal region are as follows:  
         [0203]    GG=0.0028-inches  
         [0204]    HH=0.007-inches  
         [0205]    II=0.024-inches  
         [0206]    JJ=0.002-inches  
         [0207]    KK=0.020-inches  
         [0208]    LL=0.040-inches  
         [0209]    MM=0.002-inches  
         [0210]    NN=0.002-inches  
         [0211]    OO=0.002-inches  
         [0212]    conductor thickness=0.0004-inches  
         [0213]    stiffener thickness=0.0008-inches  
         [0214]    It should be noted with respect to flexure  590 , as well as all of the other flexures previously described in which a hinge is located near the distal end of the flexure, that it is sometimes preferred to replace the hinge with a pre-bend. Such a bend is in the range of approximately 1°-4° around an axis parallel to the X axis (rotation of the distal end of the flexure upward out of the plane containing the flexure body). Fabricating a bend near the distal tip of the flexure is an extra manufacturing step in comparison to a process for manufacturing a flat flexure with a proximal hinge. However, a proximal bend is sometimes preferred over a proximal hinge because it improves vibrational stability and is more robust to shock. For example, FIG. 40D shows schematically a side view of flexure  599   d  which includes a main body portion  599   e  and a distal end portion  599   f . The distal end portion  599   f  is slightly bent at point  599   g  with respect to main body portion  599   e . Angle α, i.e., the degree of pre-bending is approximately 1-4°.  
       Methods of Production  
       [0215]    Various combinations of machining and chemical etching steps may be used to construct flexures of the present invention.  
       EXAMPLE 1  
       [0216]    Multiple sets of flexure layers are cut out of single sheets. For example, FIG. 41 shows a sheet  600  with four quadrants  602 ,  604 ,  606  and  608 . A set of laminated flexures is produced simultaneously in each quadrant. The following figures and description focus on only a single quadrant.  
         [0217]    A 1-mil. layer of stainless steel is mechanically (laser) cut out in the pattern shown in FIG. 42. Cut-out section  610  defines the hinge, and cut-outs such as  612  form rectangular windows for wire bonding.  
         [0218]    A second sheet of adhesive is cut with the same pattern as shown in FIG. 42. If the adhesive is attached to the 1-mil. stainless steel layer prior to cutting, both layers can be cut simultaneously.  
         [0219]    A conductive layer is mechanically cut out of a 0.5-mil. thick stainless steel sheet, according to the pattern  613  shown in FIG. 43, so that all conductors are electrically isolated after the final cut is made, as explained below. The material is then cleaned and gold plated on both sides of the sheet in region PP.  
         [0220]    The alignment holes are then used to align the layers on tooling pins. The layers are pressed to specified loads and heated in an oven to promote curing of the adhesive.  
         [0221]    The laminant is cut with a laser to define the beam shape  614  as shown in FIG. 44. The cut either defines individual beams  614  or “combs”  616  of beams.  
         [0222]    [0222]FIG. 45 shows a composite of all cuts.  
         [0223]    [0223]FIG. 46 shows a final beam, essentially corresponding to the flexure illustrated in FIGS. 2 and 2B.  
         [0224]    The flexure shown in FIG. 46 has the following dimensions:  
         [0225]    A=40 mils.  
         [0226]    B=20 mils.  
         [0227]    C=350 mils.  
         [0228]    D=390 mils.  
         [0229]    E=430 mils.  
         [0230]    F=24 mils.  
         [0231]    G=10 mils.  
         [0232]    H=12 mils.  
         [0233]    I=21 mils.  
         [0234]    J=44 mils.  
         [0235]    K=60 mils.  
       EXAMPLE 2  
       [0236]    The second manufacturing example employs chemical etching and/or laser cutting steps. Three sets of conductive layers are cut out from areas  330 ,  332  and  334  of one sheet  336 , as shown in FIG. 47. The following description and drawings refer to the production of a single set of flexures from area  330 . Alternatively, a continuous sheet of adhesive can be applied, then cut out by plasma etching after the conductor and stiffener layers are laminated.  
         [0237]    A 0.5-mil. thick stainless steel conductor layer is patterned as shown in FIG. 48. Pattern  340  is cut out either by chemical etching or laser cutting. During the production process, conductor pairs remain attached to adjacent conductor pairs by tabs  342 . A corresponding 1-mil. thick stainless steel stiffener layer is chemically etched or laser cut according to pattern  343  shown in FIG. 49. Adjacent stiffeners are held together by tabs  344  and  346 . An adhesive layer is applied either by stamping or laser cutting.  
         [0238]    A 0.5-mil. thick layer of gold is plated onto the conductors. The gold may be plated onto the entire conductor surface (preferred for stainless steel) or may be confined to the electrical bonding regions (preferred for beryllium copper).  
         [0239]    The layers are aligned and bonded under temperature and pressure.  
         [0240]    Finally, individual flexures are separated from each other by mechanically shearing or laser cutting tabs  342 ,  344  and  346 .  
         [0241]    Other methods of producing laminant suspensions such as the ones disclosed in U.S. Pat. No. 4,991,045 and No. 5,187,625 (both are incorporated here by reference) have been developed by Hutchinson Technology Inc. of Hutchinson, Minn. and are generally applicable to the flexures disclosed in this application.  
       EXAMPLE 3  
       [0242]    The following technique is used to attach the transducer chip.  
         [0243]    Solder paste is applied with a stencil to the chip or beam (conductors).  
         [0244]    The beam and the chip are aligned and the solder is heated to its melting point either locally with hot air, laser or infrared heating, or placed in an oven.  
       EXAMPLE 4  
       [0245]    Another method for attaching the transducer chip involves laser soldering. First, tin is deposited on gold bonding pads on the chip. Second, a laser is used to heat the gold and tin through small holes (example, holes  90  in FIGS. 2 and 3A) in the metal (stiffener) or by heating the metal directly. The tin and gold melt to form a eutectic bond.  
       EXAMPLE 5  
       [0246]    The following process is used to attach a damper for the purpose of attenuating vibrations. Damping material can be applied either before or after patterning.  
         [0247]    In a pre-patterning technique, damper (viscoelastic polymer on constraining layer) is stamped or cut with a laser to define the shape. Each damper is then aligned individually and then applied to each beam.  
         [0248]    In a post-patterning process, a square of damping material with constraining layer is applied to the beam or comb without precise alignment. A laser is then used to trim the shape of the damping material to be slightly larger than the beam shape.  
       EXAMPLE 6  
       [0249]    The following techniques are used to lap a single pad on a chip, for example, 97 in FIGS. 3B and 3C.  
         [0250]    First, the beams are made on a comb with relatively long fingers. The comb is placed in a “lapper/tester” machine which loads the beam onto a rough disk for lapping. Electrical connection is made through the metal in these fingers (an extension of the beam conductors).  
         [0251]    The machine individually twists the comb fingers and uses the magnetic signal as a lapping stop indicator to achieve “roll” facets.  
         [0252]    Pitch facets are achieved by changing the Z-height and thereby changing the angle at the beam tip.  
         [0253]    Magnetic performance may also be tested in the process.  
       EXAMPLE 7  
       [0254]    The following technique is used for lapping a three-pad chip, such as the one employed in the gimbaling flexures described above. Since the gimbal compensates for static tolerances, only a flat lap is required to achieve full signal quickly in the drive. Therefore, a shorter, simpler comb may be used with a simpler lapping machine. This machine loads the beams to a given Z-height, exposing the pole and testing.  
         [0255]    It is also possible to lap the chip pad prior to attaching the chip to the beam.  
         [0256]    [0256]FIGS. 50A and 50B schematically illustrate modified forms of transducer chips. In contrast to the rectangular transducer chips previously described, the chips shown in FIGS. 50A and 50B have different shapes for the purposes of: (a) maximizing the lateral and longitudinal distances between contact pads; (b) minimizing the weight of the transducer chip; and (c) maximizing the efficient use of materials in the chip-making process. The T-shaped and triangle-shaped transducers, as shown in FIGS. 50A and 50B, respectively, are particularly useful chip designs where a tri-pad arrangement is formed on the bottom of the chip for use in a gimbaled, disk-contacting transducer/flexure. In FIG. 50A, T-shaped chip  400  has contact pads  402   a ,  402   b  and  402   c  arranged in a triangular configuration. Similarly, in FIG. 50B, triangular chip  410  has three contact pads  412   a ,  412   b  and  412   c , again arranged in a triangular configuration. The shapes and dimensions of the chip are also dictated by the particular coil structure which is typically embedded in the chip.  
         [0257]    Although numerous embodiments of the invention have been described in detail above, it is apparent that many other modifications are enabled by the disclosure and encompassed in spirit and scope by the claims set forth below. For example, while most all of the embodiments specifically described above are transducer/flexures which are designed to operate in contact with the surface of a medium, it is apparent that many of the principles of the present invention have application to non-contacting or quasi-contacting transducer/flexures, such as “flying sliders”. Flying sliders do not employ pads such as the ones described in this application, but instead employ rails or air-bearing pads. However, flying sliders frequently require gimbaling mechanisms, and face many similar mechanical accommodation challenges as do contacting transducer/flexures. The fact that most of the embodiments described in this application are shown with contacting pads, should not be viewed in any way as a limitation on the applicability of the present invention to non-contacting or quasi-contacting head/flexure systems.  
         [0258]    Further, it is important to recall that many of the features of the present invention can be employed to great advantage with mediums other than rigid disks—for example, with drums, floppy disks, tape, etc.