Abstract:
A head suspension for supporting a head slider over a rigid disk in a dynamic storage device having a component that includes a compliant feature adapted to engage a first pin and a datum engaging surface spaced from the compliant feature. The component being locatable relative to a datum by manipulation of the component with respect to the datum and a first pin to cause the first pin to engage and deflect the compliant feature when the datum engaging surface of the component is engaged and positioned with respect to the datum. The head suspension also including a second component having a pin engaging feature and possibly a datum engaging surface alignable with the compliant feature and datum engaging surface of the first component, respectively. The pin engaging feature of the second component being compliant or non-compliant. The compliant and non-compliant features being usable for locating head suspension components, such as load beams, flexures, and base plates, relative to each other or to tooling for head suspension fabrication purposes. The compliant and non-compliant features also being usable for locating other types of small precision components relative to a datum or to each other. A method for locating a component relative to a datum using a compliant feature formed within the component is also provided.

Description:
RELATED APPLICATION  
       [0001]    This application is a divisional of U.S. patent application Ser. No. 09/397,940, filed on Sep. 17, 1999, entitled “Method of Making a Head Suspension with Compliant Feature for Component Location,” and claims priority therefrom. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to an improved head suspension having a compliant feature and associated tooling, for efficiently and accurately locating components during assembly of the head suspension.  
         BACKGROUND OF THE INVENTION  
         [0003]    In a dynamic storage device, a rotating disk is employed to store information in small magnetized domains strategically located on the disk surface. The disk is attached to and rotated by a spindle motor mounted to a frame of the disk storage device. A “head slider” (also commonly referred to simply as a “slider”) having a magnetic read/write head is positioned in close proximity to the rotating disk to enable the writing and reading of data to and from the magnetic domains on the disk. The head slider is supported and properly oriented in relationship to the disk by a head suspension that provides forces and compliances necessary for proper slider operation. As the disk in the storage device rotates beneath the slider and head suspension, the air above the disk similarly rotates, thus creating an air bearing which acts with an aerodynamic design of the head slider to create a lift force on the head slider. The lift force is counteracted by the head suspension, thus positioning the slider at a height and alignment above the disk which is referred to as the “fly height.” 
           [0004]    Typical head suspensions include a load beam, a flexure, and a base plate. The load beam normally includes a mounting region at a proximal end of the load beam for mounting the head suspension to an actuator of the disk drive, a rigid region, and a spring region between the mounting region and the rigid region for providing a spring force to counteract the aerodynamic lift force acting on the slider described above. The base plate is mounted to the mounting region of the load beam to facilitate the attachment of the head suspension to the actuator. The flexure is positioned at the distal end of the load beam, and typically includes a gimbal region having a slider mounting surface to which the slider is mounted and thereby supported in read/write orientation with respect to the rotating disk. The gimbal region is resiliently moveable with respect to the remainder of the flexure in response to the aerodynamic forces generated by the air bearing.  
           [0005]    In one type of three-piece head suspension, the flexure is formed as a separate component and further includes a load beam mounting region that is rigidly mounted at the distal end of the load beam using conventional means, such as spot welds. In such a flexure, the gimbal region extends distally from the load beam mounting region of the flexure and includes a cantilever beam to which the slider is mounted. An often spherical dimple that extends between the load beam and the slider mounting surface of the flexure is formed in either the load beam or the slider mounting surface of the flexure. The dimple transfers the spring force generated by the spring region of the load beam to the flexure and the slider to counteract the aerodynamic force generated by the air bearing between the slider and the rotating disk. In this manner, the dimple acts as a “load point” between the flexure/slider and the load beam. The load point dimple also provides clearance between the cantilever beam of the flexure and the load beam, and serves as a point about which the slider can gimbal in pitch and roll directions in response to fluctuations in the aerodynamic forces generated by the air bearing.  
           [0006]    Electrical interconnection between the head slider and circuitry in the disk storage device is provided along the length of the head suspension. Conventionally, conductive wires encapsulated in insulating tubes are strung along the length of the head suspension between the head slider and the storage device circuitry. Alternatively, an integrated lead head suspension, such as that described in commonly assigned U.S. Pat. No. 5,491,597 to Bennin et al., that includes one or more conductive traces bonded to the load beam with a dielectric adhesive can be used to provide electrical interconnection. Such an integrated lead head suspension may include one or more bonding pads at the distal end of the traces to which the head slider is attached and that provide electrical interconnection to terminals on the head slider. The conductive trace can also be configured to provide sufficient resiliency to allow the head slider to gimbal in response to the variations in the aerodynamic forces.  
           [0007]    As the number and density of magnetic domains on the rotating disk increase, it becomes increasingly important that the head slider be precisely aligned over the disk to ensure the proper writing and reading of data to and from the magnetic domains. Moreover, misalignments between the head slider and the disk could result in the head slider “crashing” into the disk surface as the slider gimbals due to the close proximity of the head slider to the rotating disk at the slider fly height.  
           [0008]    The angular position of the head suspension and the head slider, also known as the static attitude, is calibrated so that when the disk drive is in operation the head slider assumes an optimal orientation at the fly height. It is therefore important that the static attitude of the head suspension be properly established. Toward this end, the flexure must be mounted to the load beam so that misalignments between the flexure and the load beam are minimized since misalignments between the load beam and flexure may introduce a bias in the static attitude of the head suspension and the head slider. It is also important that the load point dimple be properly formed on the head suspension so that it is properly positioned in relation to the head slider when the head slider is mounted to the head suspension. Misalignments between the load point dimple and the head slider may cause a torque to be exerted on the head slider, and thus affect the fly height of the head slider and the orientation of the head slider at the fly height. These concerns are emphasized when integrated leads are used to provide electrical interconnection since the bond pads of the integrated leads (to which the head slider is bonded) are directly affected by the positioning of the flexure.  
           [0009]    To assist in the alignment of the head suspension components and in the formation of head suspension features, the head suspension typically includes reference apertures that are engaged by an alignment tool. The apertures are longitudinally spaced apart and are formed in the rigid region of the load beam. In head suspensions that include a separate flexure mounted to the load beam, the flexure includes corresponding apertures formed in the load beam mounting region of the flexure. The reference apertures in the load beam and the flexure are typically circular, and are sized and positioned so as to be substantially concentric when the flexure is mounted to the load beam. In an approach illustrated in U.S. Pat. No. 5,570,249 to Aoyagi et al., rather than being circular, a distal aperture in the load beam is elongated and generally elliptical. The aperture includes a “v” shaped portion at one end.  
           [0010]    Rigid cylindrical pins on an alignment tool are used to align the individual head suspension components. The rigid pins are spaced apart an amount equal to the longitudinal spacing between the reference apertures in the components. The pins are inserted into and engage the apertures in the load beam and flexure, and in this manner concentrically align the apertures, and thus the load beam and the flexure, to one another. The components can then be fastened together, as by welding or other known processes.  
           [0011]    There are certain deficiencies and shortcomings associated with prior art head suspensions, however. Conventional reference apertures such as those described above include manufacturing tolerances that affect the interface between the alignment tool and the head suspension component. The pins on the alignment tools also include manufacturing and positioning tolerances. These tolerances are cumulative so as to affect the alignment of individual head suspension components, and affect the forming of head suspension features, such as a load point dimple. In addition, when aligning individual head suspension components, the manufacturing tolerances in the apertures of the load beam and the flexure are “stacked” together because the head suspension components are engaged by common alignment pins, thus creating additional alignment problems. An additional shortcoming is that the alignment pins must typically be manufactured somewhat undersized so as to still be useable when the flexure and load beam apertures overlap each other to create a smaller through-hole for the pins to be inserted in due to manufacturing tolerances and misalignments in the head suspension components. Moreover, because the pins of the alignment tool are spaced apart a fixed distance, the pins may not be able to engage the reference apertures due to the manufacturing tolerances in the apertures.  
           [0012]    One head suspension having aligning features that overcome the shortcomings of the described prior art, as well as a method and apparatus for forming such head suspension, is described in commonly assigned U.S. patent application Ser. No. 09/003,605 to Heeren et al. This head suspension includes a load beam and a flexure wherein the load beam has a first load beam aperture formed in the load region of the load beam. The flexure comprises a gimbal region and a load beam mounting region, and is mounted at a distal end of the load beam. The flexure has a first flexure aperture formed in the load beam mounting region that is adjacent and coincident with the first load beam aperture when the flexure is aligned over the load beam. An elongated alignment aperture is formed in one of the load beam and the flexure, and a proximal alignment aperture and distal alignment aperture are formed in the other of the load beam and the flexure. The elongated aperture overlaps at least a portion of each of the proximal alignment aperture and the distal alignment aperture so that the proximal perimeter edge of the elongated alignment aperture encroaches upon the proximal alignment aperture and the proximal perimeter edge of the distal alignment aperture encroaches upon the elongated alignment aperture. This configuration of apertures allows the flexure and load beam to be independently aligned relative to each other by dual moving pins of an alignment tool that engage the proximal perimeter edge of the distal alignment aperture and the proximal perimeter edge of the elongated alignment aperture.  
           [0013]    An ongoing need exists, however, for improved head suspension designs for use in dynamic storage devices and for supporting head sliders over disk surfaces wherein features are formed in the head suspensions that assist in the efficient and accurate alignment of the head suspension components. Such need is felt in the areas of part manufacturability, cost savings, tool construction, and other tool and alignment related areas.  
         SUMMARY OF THE INVENTION  
         [0014]    The present invention meets the ongoing need for improved head suspension designs by providing a head suspension for supporting a head slider over a rigid disk in a dynamic storage device. The head suspension includes compliant features formed in one or more components of the head suspension for use in accurately locating the components relative to tooling or to one another. Such compliant features may also be used for accurately locating other types of small precision components.  
           [0015]    The head suspension has a component that includes a compliant feature adapted to be engaged and deflected by a first pin. The component may also include a datum engaging surface spaced from the compliant feature that is adapted to be engaged and positioned relative to a datum. The component is locatable relative to the datum by manipulation of the component with respect to the datum and the first pin. The manipulation causes the first pin to engage and deflect the compliant feature when the datum engaging surface of the component is engaged and positioned with respect to the datum. The compliant feature may be formed in a detachable portion of the head suspension component, which is later detached during head suspension formation. The compliant feature may be formed as a compliant aperture, and the datum engaging surface may be formed as a second aperture with a second pin forming the datum.  
           [0016]    The head suspension also may include a second component having a pin engaging feature alignable with the compliant feature of the first component, such that the first pin engages the pin engaging feature and engages and deflects the compliant feature during manipulation. The second component may also include a datum engaging surface alignable with the datum engaging surface of the first component, such that both the datum engaging surfaces are engaged and positioned with respect to the datum during manipulation. The pin engaging feature of the second component may also be a compliant feature. The compliant feature, pin engaging feature and datum engaging surfaces are usable for locating the head suspension components, such as load beams, flexures, and base plates, relative to each other or to tooling for head suspension fabrication purposes.  
           [0017]    A method for locating a component, including a component of a head suspension assembly, relative to a fixed datum is also provided. The method includes the steps of providing a component having a compliant feature and a datum engaging surface; providing a datum for engaging the datum engaging surface; providing a first pin for engaging the compliant feature; and manipulating the component with respect to the datum and first pin. The manipulation causes the first pin to engage and deflect the compliant feature when the datum engaging surface of the component is engaged and positioned with respect to the datum. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    [0018]FIG. 1 is a plan view of the head suspension mounted over a rigid disk in a dynamic storage device.  
         [0019]    [0019]FIG. 2 is a perspective view of the head suspension of FIG. 1 including one embodiment of a compliant feature in a flexure component.  
         [0020]    [0020]FIG. 3 is a plan detail view of the head suspension of FIG. 2 showing the compliant feature and a portion of a load beam.  
         [0021]    [0021]FIG. 4 is an exploded view of a portion of the head suspension of FIGS. 2 and 3 showing the overlap of the flexure over the load beam.  
         [0022]    [0022]FIG. 5 is a plan detail view of the head suspension of FIG. 3 showing the compliance of the compliant feature in the flexure.  
         [0023]    [0023]FIG. 6 is a plan detail view of a head suspension including another embodiment of a compliant feature in the flexure component.  
         [0024]    [0024]FIG. 7 is a plan detail view of a head suspension including yet another embodiment of a compliant feature in the flexure component.  
         [0025]    [0025]FIG. 8 is a plan detail view of a head suspension including even another embodiment of a compliant feature in the flexure component.  
         [0026]    [0026]FIG. 9 is a plan view of a head suspension including one embodiment of a compliant feature in both the flexure and load beam components.  
         [0027]    [0027]FIG. 10 is an exploded view of the head suspension of FIG. 9 showing the overlap of the flexure over the load beam.  
         [0028]    [0028]FIG. 11 is a plan view of a head suspension including another embodiment of a compliant feature in both the flexure and load beam components.  
         [0029]    [0029]FIG. 12 is a plan view of a head suspension including yet another embodiment of a compliant feature in both the flexure and load beam components.  
         [0030]    [0030]FIG. 13 is an exploded view of the head suspension of FIG. 12 showing the overlap of the flexure over the load beam.  
         [0031]    [0031]FIG. 14 is a plan view of a head suspension including one embodiment of a compliant feature in the load beam for use in locating a base plate.  
         [0032]    [0032]FIG. 15 is a plan view of the load beam of a head suspension located on a detachable carrier portion including a compliant feature on the carrier portion.  
         [0033]    [0033]FIG. 16 is a side cross-sectional view of one embodiment of a tool for manipulating head suspension components having a compliant feature.  
         [0034]    [0034]FIG. 17 is a side cross-sectional view of another embodiment of a tool for manipulating head suspension components having a compliant feature.  
         [0035]    [0035]FIG. 18 is a side cross-sectional view of the tool of FIG. 17 showing the tool during actuation. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]    With reference to the attached Figures, it is to be understood that like components are labeled with like numerals throughout the several Figures. The present invention includes a head suspension having structures useful in minimizing misalignments in the head suspension and a method of using such structures in manufacturing such a head suspension or other small precision components. FIG. 1 illustrates a rigid disk drive  8  that includes a head suspension  10 . Head suspension  10  resiliently supports a head slider  14  at a fly height above a rigid disk  9  during operation, as described above in the Background section. Head suspension  10  is connected to a rotary actuator  13 , as is known, for accessing data tracks provided on the surface of rigid disk  9 . Head suspension  10  could otherwise be utilized with a linear type actuator, as is also well known.  
         [0037]    FIGS.  2 - 5  show head suspension  10  in greater detail. Head suspension  10  has a longitudinal axis  12 , and is comprised of a base plate  16 , a load beam  20 , and a flexure  40 . Base plate  16  is mounted to a proximal end  22  of load beam  20 , and is used to attach head suspension  10  to actuator  13  in the disk drive  8 . A boss  17  on base plate  16  passes through a boss aperture (not shown) in the proximal end  22  of load beam  20 , and an opening  18  within the boss  17  provides the attachment mechanism for attaching the head suspension  10  to the actuator  13 .  
         [0038]    Slider  14  is mounted to flexure  40 , and as the disk  9  in the disk drive  8  rotates beneath head slider  14 , an air bearing is generated between slider  14  and the rotating disk  9  which creates a lift force on head slider  14 . This lift force is counteracted by a spring force generated by the load beam  20  of head suspension  10 , thereby positioning the slider  14  at an alignment above the disk  9  referred to as the “fly height.” As described in detail below, flexure  40  provides the compliance necessary to allow head slider  14  to gimbal in response to small variations in the air bearing generated by the rotating disk  9 .  
         [0039]    Load beam  20  of head suspension  10  has an actuator mounting region  26  at proximal end  22 , a load region  28  adjacent to a distal end  24 , a resilient spring region  30  positioned adjacent actuator mounting region  26 , and a rigid region  32  that extends between spring region  30  and load region  28 . Resilient spring region  30  generates a predetermined spring force that counteracts the lift force of the air bearing acting on head slider  14 . Toward this end, spring region  30  can include an aperture  31  to control the spring force generated by spring region  30 . Rigid region  32  transfers the spring force to load region  28  of load beam  20 . A load point dimple  34  (shown in FIG. 4) is formed in load region  28 , and contacts flexure  40  to transfer the spring force generated by spring region  30  to flexure  40  and head slider  14 . A load point dimple (not shown) can alternatively be formed in flexure  40  to extend toward and contact load region  28  of load beam  20 .  
         [0040]    In the head suspension shown in FIGS.  2 - 5 , flexure  40  is formed as a separate component and is mounted to load beam  20  near the distal end  24 . Flexure  40  includes a gimbal region  42  and a load beam mounting region  44 . Load beam mounting region  44  overlaps and is mounted to a portion of rigid region  32  using conventional means, such as spot welds. Gimbal region  42  of flexure  40  provides the necessary compliance to allow head slider  14  to gimbal in both pitch and roll directions about load point dimple  34  in response to fluctuations in the air bearing generated by the rotating disk  9 . Toward this end, gimbal region  42  includes a cantilever beam  46  having a slider mounting surface  47  to which head slider  14  is attached. Cantilever beam  46  is attached to cross piece  45 , which is connected at each end to first and second arms  48  and  49 , respectively, of flexure  40 . Cantilever beam  46  is resiliently movable in both pitch and roll directions with respect to the remainder of flexure  40 , and thereby allows head slider  14  to gimbal. Load point dimple  34  (when formed in load region  28 ) contacts the surface opposite the slider mounting surface  47  of cantilever beam  46  to transfer the spring force generated by spring region  30  of load beam  20  to head slider  14 , and further to provide a point about which head slider  14  and cantilever beam  46  can gimbal.  
         [0041]    Due to the high density of magnetic domains on the disk  9 , and further due to the close proximity of head slider  14  to the rotating disk  9  at the slider fly height, it is important that head slider  14  be properly aligned over the disk  9 . Toward this end, it is highly desirable to minimize any misalignments in head suspension  10 , particularly in the alignment of the flexure  40  with respect to the load beam  20 , and of the base plate  16  with respect to the load beam  20 . It is also highly desirable to minimize any mislocation of the load point dimple  34  relative to the load beam  20 , any mislocation of the head slider  14  relative to the flexure  40 , or any misalignment between the head slider  14  and the load point dimple  34  when head slider  14  is mounted to head suspension  10 . Misalignments and mislocation may occur due to tolerance stack up between the components of the head suspension  10 , and between the head suspension  10  and necessary tooling used in the manufacturing process.  
         [0042]    Referring now to FIGS. 3 and 4, in order to minimize the misalignments and mislocations in head suspension  10 , head suspension  10  includes a series of structures formed in the components of head suspension  10 . In FIG. 4, the load beam  20  includes a pin engaging feature referred to as a first load beam aperture  50  located in the rigid region  32  near the spring region  30 , and a datum engaging surface referred to as a second load beam aperture  60  located in the load region  28  near the distal end  24 . The flexure  40  includes two corresponding structures, a compliant feature referred to as a compliant first flexure aperture  70  located in the load beam mounting region  44  and a datum engaging surface or second flexure aperture  80  located near the gimbal region  42 , respectively. As shown in FIG. 3, when the flexure  40  is mounted to the load beam  20 , the compliant feature  70  overlaps the pin engaging feature  50  (shown in dashed lines) and the datum engaging surface of the flexure  80  overlaps the datum engaging surface of the load beam  60 .  
         [0043]    In one embodiment, the compliant first flexure aperture  70  is formed to include a central opening  72  located within a central planar region  71 . The central planar region  71  is surrounded by a pair of bounding openings  73  that are separated by two bridge portions  76 ,  77  that tie the central planar region  71  to the remainder of the flexure  40 . Two slots  74 ,  75  are formed transversely adjacent the bounding openings  73 , creating narrow strips of flexure  78 ,  79  coupled to the bridge portions  76 ,  77 , respectively. The configuration of the compliant aperture  70  is designed to be compliant along a longitudinal axis in the plane of the flexure  40 , and rigid perpendicular to the longitudinal axis in the plane of the flexure  40 .  
         [0044]    The first load beam aperture  50 , or pin engaging feature, has a substantially diamond shape with ‘V’shaped ends  51 ,  52  aligned along the longitudinal axis  12 . As shown in FIG. 3, the first load beam aperture  50  is larger than the central opening  72  of the compliant first flexure aperture  70 . Although the first load beam aperture  50  is shown with ‘V’ shaped ends, it is to be understood that other suitable structures may also be used. These structures include, but are not limited to apertures having round, oval, or oblong shapes, apertures having variations on these shapes with one or more ‘V’ shaped ends, or other structures formed with a surface or surfaces that converge to engage a pin in a set location.  
         [0045]    The second apertures or datum engaging surfaces  60  and  80  are shown as apertures having a substantially oblong shape with one round end  61 ,  81  and one ‘V’ shaped end  62 ,  82 . The ‘V’ shaped ends  62 ,  82  are located on the side toward the distal end  24  of the load beam  20  pointing away from the first apertures  50  and  70 , and are designed to have converging surfaces that engage a pin or other datum structure in a desired position. These two apertures  60 ,  80  are substantially the same size.  
         [0046]    To align the flexure  40  relative to the load beam  20  during formation of the head suspension  10 , the flexure  40  is placed over the load beam  20 , overlapping the first apertures  70  and  50 , respectively, and the second apertures  80  and  60 , respectively. As shown in FIG. 3, a fixed second alignment pin  95  serving as a datum is inserted through the overlapped apertures  80  and  60 , and a first alignment pin  90  is inserted through the overlapped apertures  70  and  50 . The ‘V’ shaped ends  62 ,  82  of the overlapped second apertures  60 ,  80  engage the alignment pin  95 . Referring now to FIG. 5, in one embodiment, the alignment pins  90 ,  95 , the compliant first flexure aperture  70  and the first load beam aperture  50  are manipulated relative to one another to place the load beam  20  and flexure  30  in tension between the alignment pins  90 ,  95 . This manipulation causes the first pin  90  to engage and deflect the compliant first flexure aperture  70  until the first pin  90  is in contact with the ‘V’ end  52  of the larger first load beam aperture  50 , and the flexure  40  and the load beam  20  are located relative to the datum pin  95 .  
         [0047]    To achieve this result, the compliant first flexure aperture  70  moves longitudinally in the plane of the flexure  40  causing partial deflection of the compliant aperture  70 . As shown in FIG. 5, as the pin  90  moves away from pin  95 , the central planar region  71  moves in the same direction causing slot  74  to contract and slot  75  to expand. Both narrow strips  78 ,  79  also flex at bridges  76 ,  77 , imparting a slight ‘V’ shape into the strips  78 ,  79 . Once the two alignment pins  90 ,  95  are in position, the flexure  40  is located relative to the load beam  20  so that further manufacturing processes may be performed, such as securing the flexure  40  to the load beam  20 .  
         [0048]    The compliant first flexure aperture  70 , shown in FIGS.  2 - 5 , provides the compliance necessary to adjust for tolerance stack up between the components and the tooling. It is to be understood, however, that other suitable configurations of compliant features may also be used and are within the scope of the present invention. Such configurations may include, but are not limited to, the following examples.  
         [0049]    In FIG. 6, an alternate embodiment of a compliant feature or compliant first flexure aperture  100  is shown formed in flexure  40 , which has been overlaid on load beam  20 . A corresponding pin engaging feature or first load beam aperture  110  (shown in dashed lines) is formed in load beam  20 . Suitable datum engaging surfaces or second load beam and flexure apertures  60 ,  80  are formed in the load beam  20  and flexure  40 , respectively, and overlapped as described in the previous embodiment. Compliant first flexure aperture  100  includes a central opening  101  having a generally oblong shape with a ‘V’ shaped end  102  on the spring region  30  side and a slot portion  103  extending along the longitudinal axis  12 . A narrow strip  104 , formed from flexure material between the central opening  101  and a corresponding contoured channel  105 , follows the contour of the central opening  101  around more than half of the central opening  101 . The first load beam aperture  110  underlying the compliant aperture  100  has a generally oblong shape with a ‘V’ shaped end  111  that is generally similar to the shape of the central opening  101 , but larger in size. When the flexure  40  and load beam  20  are placed in tension between alignment pin  90  and datum pin  95 , while the flexure  40  and load beam  20  are manipulated relative to pin  90  and the datum pin  95 , the narrow strip  104  deflects toward the contoured channel  105  at the slot portion  103 . The slot portion  103  enlarges until the alignment pin  90  contacts the ‘V’ end  111  of the first load beam aperture  110 , locating the flexure  40  relative to the load beam  20  and the datum pin  95 .  
         [0050]    In FIG. 7, another alternate embodiment of a compliant first flexure aperture  120  is shown overlapped with a first load beam aperture  130  (shown in dashed lines). Compliant aperture  120  includes a substantially rectangular opening  121  having a ‘V’shaped end  122  on the side of the spring region  30 , and a ‘V’ shaped slot  123  adjacent the opening  121  separated by a narrow strip  124  formed of flexure material. The first load beam aperture  130  is also substantially rectangular in shape with a ‘V’ shaped end  131 , but is slightly larger in size than the opening  121 . When the head suspension  10  is manipulated relative to pin  90  and the datum pin  95 , the narrow strip  124  deflects toward the slot  123  until the pin  90  contacts the ‘V’end  131  of the first load beam aperture  130 .  
         [0051]    In FIG. 8, yet another alternate embodiment is shown of a compliant first flexure aperture  140  overlapping a first load beam aperture  150  (shown in dashed lines). The compliant aperture  140  includes a central opening  141  that is generally rectangular in shape with a modified ‘W’ shaped end  142  on the side of the spring region  30 . Adjacent the central opening  141  is a expansion opening  143  formed as a somewhat mirror image of the central opening  141 . A narrow strip  144  having a corresponding modified ‘W’shape separates the central opening  141  from the expansion opening  143 . The first load beam aperture  150  has a generally rectangular shape with a ‘V’ shaped end  151 , and is sized longitudinally larger than the central opening  141 . When the head suspension  10  is manipulated relative to pin  90  and the datum pin  95 , the narrow strip  144  deflects toward the expansion opening  143  until the pin  90  contacts the ‘V’ end  151  of the first load beam aperture  150 .  
         [0052]    The compliant feature ( 70 ,  100 ,  120 ,  140 ) is preferably formed in the flexure  40 , as described above, when coupled with a non-compliant pin engaging feature  50  because the material of the flexure  40  is generally thinner and more compliant than that of the load beam  20 . However, the compliant feature may be formed in the load beam  20  instead of the flexure  40  if desired. Alternately, the compliant feature may be formed in a carrier strip attached to the flexure or a series of flexures, or the load beam or a series of load beams, as will be described in more detail below with reference to FIG. 15.  
         [0053]    In some situations, it may be desirable to use compliant features in both the flexure  40  and the load beam  20  in order to effectively locate the head suspension components relative to each other and/or to necessary tooling. Referring now to FIGS. 9 and 10, another embodiment of a head suspension  210  is shown having a load beam  220  with a flexure  240  overlaid on it. The load beam  220  and the flexure  240  of head suspension  210  include the same general features as their counterparts in head suspension  10  described above. As shown in FIG. 10, in particular, load beam  220  includes a compliant feature or compliant first load beam aperture  250  and a datum engaging surface or second load beam aperture  260 . Flexure  240  includes another compliant feature or compliant first flexure aperture  270  and another datum engaging surface or second flexure aperture  280 . When flexure  240  is overlaid over load beam  220  as shown in FIG. 9, the flexure structures  270  and  280  overlap the corresponding load beam structures  250  and  260 , respectively.  
         [0054]    The second load beam and flexure apertures  260  and  280  have a generally oblong shape with ‘V’ shaped ends  262  and  282 , respectively, for engaging a datum such as second alignment pin  295 . The compliant first load beam and flexure apertures  250  and  270  include primary openings  251 ,  271  and ‘W’ shaped flex openings  252 ,  272  created by flexible fingers  253 ,  273  formed in the load beam  220  and flexure  240 , respectively. The primary openings  251 ,  271  are shown to be substantially rectangular in shape, but may be oval, round or other suitable shape. The flexible fingers  253 ,  273  angle inward toward the longitudinal axis  212  forming ‘V’ shaped ends for the primary openings  251 ,  271 . Gaps  254 ,  274  between the flexible fingers  253 ,  273 , coupled with channel openings  255 ,  275  adjacent the flexible fingers  253 ,  273 , form the ‘W’shape of the flex openings  252 ,  272 , respectively.  
         [0055]    Alignment pin  295  is inserted into the overlapped second apertures  260 ,  280 , and then alignment pin  290  is inserted into the overlapped first apertures  250 ,  270 . Pin  290  and head suspension  210  are then manipulated relative to one another, causing the pin  290  to engage and deflect compliant first apertures  250 ,  270  and placing the flexure  240  and load beam  220  in tension between the two alignment pins  290 ,  295 . The ‘V’ shaped ends  262 ,  282  of the second apertures  260 ,  280  then engage the datum pin  295 , thereby locating the flexure  240  and load beam  220  relative to the datum  295  and each other.  
         [0056]    In FIG. 11, an alternate embodiment of head suspension  210  is shown having overlapped second apertures  260  and  280  and a different configuration of overlapped compliant first load beam aperture  300  and compliant first flexure aperture  310 . Since both first apertures are the same, only the details of the compliant first flexure aperture  310 , shown over the first load beam aperture  300  in FIG. 11, will be described.  
         [0057]    Compliant first flexure aperture  310  includes an irregularly shaped opening  311  with a rectangular portion  312  on the distal side. Two hook shaped fingers  313  formed within the opening  311  create an open ‘V’ shaped region  314 , two outer arm slots  315 , and a modified ‘W’ shaped portion  316  located on the proximal side. Alignment pin  295  is initially positioned within the overlapped second apertures  260  and  280 , then alignment pin  290  is positioned in the open ‘V’ shaped region  314  and manipulated relative to the head suspension  210 . Alignment pin  290  deflects the hook shaped fingers  313  until alignment pin  295  is positioned relative to both the flexure  240  and load beam  220 .  
         [0058]    As an alternative to using alignment pins to place the components in tension between the pins, as discussed in the above described embodiments, alignment pins may be used to place the components in compression between the pins to achieve the same location result. The directions of both the compliant features (or the compliant feature and pin engaging feature) and the directions of the datum engaging surfaces in the above described embodiments may be reversed so that the converging surfaces of the datum engaging surfaces are directed toward the compliant features and the converging surfaces of the compliant features are directed toward the second apertures. Once the pins are inserted into their respective apertures, manipulation of the components and the pins causes the components to be placed in compression between the pins, and thus alignment of the components relative to each other and the datum would be achieved.  
         [0059]    Referring now to FIGS. 12 and 13, one embodiment for implementing this situation is shown for head suspension  410  having flexure  440  overlaid over load beam  420 . Similar datum engaging surfaces or second apertures  460  and  480  overlap to be used with datum alignment pin  495 . However, ‘V’ shaped ends  462  and  482  are located on a side away from distal end  424  of head suspension  410 , pointing toward compliant features  450  and  470 , instead of away from these features  450 ,  470  as was shown in the prior embodiments.  
         [0060]    Compliant feature or compliant first load beam aperture  450  is formed adjacent to and in connection with an aperture  431  provided to control the spring force generated by spring region  430 . Aperture  431  forms the primary opening  451  of the compliant first load beam aperture  450 , and a ‘W’ shaped flex opening  452 , created by flexible fingers  453  formed in the load beam  420 , is formed adjacent aperture  431 . The flexible fingers  453  angle inward toward the longitudinal axis  412  forming a ‘V’ shaped end for the primary opening  451  pointing toward the second aperture  460 . A gap  454  between the flexible fingers  453  coupled with channel openings  455  adjacent the flexible fingers  453  form the ‘W’ shape of the flex opening  452 .  
         [0061]    Compliant feature  470 , on the other hand, is not an aperture in that it does not include a primary opening, but instead is actually a compliant notch-type structure positioned at the proximal end  422  of flexure  440 . This compliant structure includes a ‘W’ shaped flex opening  472 , corresponding to the ‘W’ shaped flex opening  452  of the load beam  420 . Flexible fingers  473  formed in the flexure  440  angle inward toward the longitudinal axis  412  forming a ‘V’ shaped notch  476  pointing toward the second aperture  480 . A gap  474  between the flexible fingers  473  coupled with channel openings  475  adjacent the flexible fingers  473  form the ‘W’ shape of the flex opening  472 .  
         [0062]    With this configuration, datum alignment pin  495  is inserted through the overlapped apertures  460 ,  480 , and alignment pin  490  is inserted through compliant aperture  450  and engages compliant feature  470 . Alignment pin  490  then places the components in compression relative to the datum  495 , with datum pin  495  engaging the ‘V’ shaped ends  462 ,  482  of the second apertures  460 , and  480 . Head suspension  410  and flexure  440  are then manipulated relative to the alignment pin  490  and datum pin  495 . This manipulation causes pin  490  to engage and deflect flexible finger  453  and  473  until pin  490  is positioned uniformly relative to both the compliant features  450  and  470  when the second apertures  460  and  480  are engaged and positioned with respect to the datum pin  495 .  
         [0063]    As would be apparent to one skilled in the art, other suitable compliant feature configurations may be formed in both the flexure  240 ,  440  and the load beam  220 ,  420 , to be used in either tension or compression, to achieve the same results as those described above. Such compliant features would include compliant elements formed within one or more head suspension components. Additionally, such compliant features used in combination with such datum engaging surfaces may be formed in other types of small precision components to provide alignment and locating capability for those components. It is to be understood that such features are within the spirit and scope of the present invention.  
         [0064]    In addition to limiting misalignments and mislocations by aiding in location of a flexure relative to a load beam, as described in the above embodiments, compliant features may also be used in head suspensions to locate a component relative to tooling or to locate other components relative to the load beam or to each other. In FIG. 14, an example of the latter is shown for a head suspension  510  including a load beam  520  and base plate  516  (shown in hidden lines). Base plate  516  includes a boss  517  having an opening  518  used to position and attach the head suspension  510  to the actuator (not shown).  
         [0065]    Load beam  520  includes a datum engaging surface  560 , similar to those described above, for engaging and positioning the load beam with respect to a datum pin  595 . The load beam  520  also includes a compliant feature or compliant boss aperture  550  provided in the proximal end  522  of load beam  520  to locate the base plate  516  relative to the load beam  520 . In one embodiment, boss  517  passes through the compliant boss aperture  550  to serve as an alignment pin, similar in function to the alignment pins described above. Compliant boss aperture  550  includes a primary opening  551  that is generally round in shape. Formed from the load beam  520  are two flexible fingers  552  configured to angle away from a longitudinal axis  512 , forming a ‘V’ shaped end on the proximal side of the primary opening  551 . A generally ‘T’ shaped slot  553  with a portion  554  passing between the two flexible fingers  552  is formed adjacent the primary opening  551 .  
         [0066]    A pin (not shown) is typically placed through boss opening  518  to facilitate manipulation of the baseplate  516 . When the boss  517  is inserted through the compliant boss aperture  550  and datum pin  595  is inserted through the datum engaging surface  560 , the load beam  520  is manipulated relative to the boss  517  and the datum pin  595 . The manipulation causes the boss  517  to deflect the flexible fingers  552  until boss  517  is positioned uniformly relative to the load beam  520 . Additional reference structures (not shown), such as a reference plane, may also be used to aid in squaring the base plate  516  relative to the load beam  520 .  
         [0067]    In an alternate embodiment, base plate  516  may be overlaid on load beam  520  such that boss  517  does not pass through the compliant boss aperture  550  but is positioned to overlap the aperture  550 . In this situation, an alignment pin (not shown) is inserted through compliant boss aperture  550  and through the overlapping opening  518  of boss  517 . The load beam  520  and base plate  516  are then manipulated relative to the alignment pin and datum pin  595  until the alignment pin engages and deflects the compliant boss aperture  550  when the datum engaging surface  560  is engaged and positioned relative to the datum pin  595 .  
         [0068]    In order to position a single component relative to tooling or other desired datum, a compliant feature or features may be formed within the component, with or without additional non-compliant features. In FIG. 10, for example, both the load beam  220  and the flexure  240  are locatable relative to a datum such as tooling on their own, in addition to being locatable relative to each other. The load beam  220  may be positioned relative to two tooling alignment pins (as shown in FIG. 9) so that further manufacturing processes may be performed on the load beam  220 . These processes may include, but are not limited to formation of the dimple  234 . The flexure  240  may be positioned relative to two tooling alignment pins for further processing, as well, including but not limited to forming gimbal features. The provided features, both compliant and non-compliant, are also available for use in future processes, including assembly, head slider attachment, head suspension mounting, or other suitable process.  
         [0069]    In FIG. 15, an alternate configuration of compliant feature placement is shown for a load beam  620 . The load beam  620  includes a detachable carrier portion  630  (or carrier strip) designed to carry multiple load beams  620  through one or more manufacturing processes, and a load portion  631  designed to perform the load beam functions. A compliant feature or compliant first aperture  650  is positioned at the proximal end  622  of the load beam  620  at the juncture between the detachable carrier portion  630  and the load portion  631 . A shear line  632  is shown in phantom positioned at this juncture, indicating the detachment position between the two load beam portions  630  and  631 . A datum engaging surface or second aperture  660  having a ‘V’ shaped end  662  is provided toward the distal end  624  of the load portion  631  of the load beam  620 .  
         [0070]    The compliant first aperture  650  has a configuration similar to those described above. A pair of flexible fingers  653  are provided in a generally ‘V’ shape in a direction away from the second aperture  660 . A datum pin  695  and then a first alignment pin  690  are inserted through the second and first apertures  650  and  660 , respectively, and the component is placed in tension between the two pins  690 ,  695  in this configuration. Manipulation of the load beam  620  relative to the datum pin  695  and first pin  690  causes engagement and deflection of the flexible fingers  653  when the datum engaging surface is engaged and positioned relative to the datum pin  695 . Necessary manufacturing processes may then be performed with a minimum of misalignment and mislocation. Once the usefulness of the detachable carrier portion  630  is finished, the load portion  631  of the load beam  620  may be detached from the detachable carrier portion  630  at the shear line  632 . The compliant first aperture  650  is then no longer available for use with the load portion  631  (and subsequent head suspension) during future handling or processing of the load beam  620 . Whether or not availability of the compliant aperture is necessary or desired depends on the ultimate configuration of the head suspension, the ultimate user of the head suspension, and other manufacturing and/or business issues.  
         [0071]    As is apparent to one of skill in the art, numerous combinations and permutations of the above described components and features may be designed depending on the needs of the head suspension manufacturer and user. Simultaneous attachment of two or more components together can be achieved using multiple features. For example, in the situation shown in FIG. 15, a flexure (not shown) could be added after the load beam  620  was positioned, wherein the flexure also included a detachable carrier portion. The flexure could include a non-compliant feature to overlap the datum engaging surface  660  and a compliant feature located in the detachable carrier portion in a manner similar to compliant feature  650  described above. The load beam apertures would be used in tension and the flexure apertures used in compression, thereby requiring only one datum engaging surface  660  within the functioning part of the head suspension, but providing effective location of both the load beam and flexure relative to tooling and each other during the manufacturing process. Many other such configurations are also possible and within the scope and spirit of the present invention.  
         [0072]    In the embodiments described above, manipulation of the head suspension relative to alignment pins may be achieved in numerous ways. In these embodiments, it is preferable that the alignment pin used with the noncompliant features, such as the datum engaging surfaces or pin engaging features, have a leading chamfer or bullet-nose to aid in insertion of the pin through a single feature or overlapped features.  
         [0073]    Referring again to FIG. 9, in the embodiment shown wherein both the flexure  240  and the load beam  220  include at least one compliant feature  250 ,  270 , alignment pin manipulation is preferably achieved using an alignment pin  290  that includes a predetermined taper. The two alignment pins  290  and  295  are maintained at a fixed distance relative to one another with the datum alignment pin  295  being straight and of a consistent diameter except for the leading chamfer or bullet-nose mentioned above. The taper of the manipulated alignment pin  290  is designed to provide a sufficient increase in diameter to engage and deflect the flexible fingers  253  of the compliant feature  250 . The taper of the alignment pin  290  works against the spring force of the flexible fingers  253  until the components are positively located against the datum pin  295 . Flexible fingers  253  may deflect both in the plane of the head suspension  210  or out of that plane.  
         [0074]    The manipulated alignment pin  290  is preferably fixed at a calculated offset distance from the designed distance between the features in order to provide removal of the stacked up tolerances of the equipment, tool and components when the components reach their positive location. In use, the fixed datum pin  295  and taper pin  290  may be pushed through the apertures of the component or components, or the component or components may be pushed onto the alignment pins, both in a direction perpendicular to a longitudinal axis of the components in the plane of the components, to achieve the same results. The distance between the axes of the two pins  290 ,  295  remains constant during manipulation of the components.  
         [0075]    Referring now to FIGS.  2 - 8 , in the embodiments shown wherein the flexure  40  includes at least one compliant feature  70 ,  100 ,  120 ,  140  and the load beam  20  includes no compliant features, a longitudinal force is required to deflect the compliant feature  70 ,  100 ,  120 ,  140  and positively locate the components relative to the datum pin  95 . With the datum pin  95  in a fixed position, the manipulated pin  90  is preferably moved relative to the datum pin  95 . Various mechanisms for providing a manipulated pin that moves relative to a fixed pin are generally known in the art.  
         [0076]    In FIG. 16, one embodiment of a tool  700  providing one fixed datum pin  795  and one movable manipulated pin  790  is shown. The tool  700  includes a top  702  and a bottom  704 . The datum pin  795  is mounted within the top  702 . A pin rocker linkage  720  is held in place between the top  702  and the bottom  704  by a spring pin  710 , a return spring  712 , a pivot  730  and an actuation spring  722 . When opposite forces are applied to the spring pin  710  and the top  702 , the spring pin  710  compresses the return spring  712  and disengages from the pin rocker linkage  720  at bore  714 . Pin rocker linkage  720  is then free to move upward, toward the top  702 , under the force of the actuation spring  722 . Movement of the pin rocker linkage  720  then rotates the movable pin  790  about pivot  730 , thereby providing the necessary manipulated pin movement to deflect the compliant feature and locate the components relative to the datum pin  795 . This tool  700  is preferably used when locating and attaching two components to one another, such as a flexure to a load beam.  
         [0077]    [0077]FIGS. 17 and 18 illustrate an alternate embodiment for a tool  800  providing one fixed datum pin  895  and one movable manipulated pin  890 . The tool  800  includes an angle block  810  coupled to a return spring  815 . An actuation punch  825  coupled to an actuation spring  820  rides along the angle block  810  at coupling  830 . The actuation punch  825  contacts the movable manipulated pin  890  above a pivot axle  840 . A pullback spring  835  keeps the movable pin  890  in vertical position when the actuation punch  825  is not being actuated by the angle block  810 . As shown in FIG. 18, when a force is applied to the angle block  810 , pushing against the return spring  815 , the actuation punch  825  moves away from the movable pin  890 . The pullback spring  835  then causes the moveable pin  890  to pivot about the pivot axle  840  providing tension motion between the pins  890  and  895  needed to deflect the compliant feature  70  and locate the component relative to the datum pin  895 . This tool  800  is preferably used to locate a single component relative to a datum for forming operations such as dimple formation.  
         [0078]    As would be apparent to one skilled in the art, other suitable mechanisms or structures may be used to deflect the compliant feature or features placing the components in tension or compression between the alignment pins and achieving the same results as those described above. For example, although it is preferable to use round alignment pins with ‘V’shaped feature configurations, differently shaped pins and/or feature configurations may be used. It is to be understood that such configurations are within the spirit and scope of the present invention.  
         [0079]    The compliant features of the present invention may be fabricated by standard industry methods. These methods may include etching, machining, stamping or other suitable processes.  
         [0080]    The present invention provides a head suspension including structures in the form of compliant features that are useful in minimizing misalignments in the formation of the head suspension. The present invention uses an alignment pin and a datum to achieve a high degree of accuracy when locating a component to a tool or a component to another component. In addition, the compliant features of the present invention are capable of adjusting for tolerance stack-ups in the equipment, tool and components of the head suspension and achieve zero clearance between the alignment pins of the tool and the locating features. Another key benefit of the present invention is the reduced need for space for locating features because these features can be placed in detachable portions of the components during the manufacturing processes and not in the functioning portion of the head suspension. Additionally, the mechanisms required for use with the compliant features of the present invention are more easily manufactured and simpler to operate. In particular, some embodiments of the compliant features require no actuation in the mechanism, but provide all necessary compliance in the feature. The overall versatility of the design possibilities, design combinations, and feature permutations, coupled with the locating effectiveness, sets apart the present invention as a significant improvement in head suspension design.  
         [0081]    Although the compliant features of the present invention have been primarily described in the context of head suspensions and head suspension components, the compliant features of the present invention are also useful for the location and alignment of other small precision components. Compliant features combined with datum engaging surfaces can be used in other situations where accurate location and alignment of one or more components relative to a datum or to each other is required. The compliant features are especially useful with small precision components having little available surface area for accommodating alignment features.  
         [0082]    Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. In addition, the invention is not to be taken as limited to all of the details thereof as modifications and variations thereof may be made without departing from the spirit or scope of the invention.