Abstract:
A terminal pressing unit collectively presses terminals of a plurality of suspensions constituting a head suspension assembly including the suspensions and an actuator block against terminals of the actuator block. A terminal connecting unit connects the terminals of the suspensions with the terminals of the actuator block.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention generally relates to a technology for connecting terminals of a plurality of suspensions constituting a suspension array with terminals of an actuator block. 
         [0003]    2. Description of the Related Art 
         [0004]    Conventionally, a head suspension assembly (HSA) is employed in a magnetic disk device to write (record) recorded data in a magnetic disk or to read (reproduce) the recorded data from the magnetic disk. 
         [0005]    In recent years, following downsizing and improved precision of magnetic disk devices, operation for electrically connecting a terminal of each of suspensions to that of an actuator block during manufacturing of an HSA that includes the suspensions and the actuator block has increasingly become so important as to influence product yield and product reliability. 
         [0006]    To connect the terminal of the suspension to the terminal of the actuator block, the following two methods are conventionally adopted. First, the terminal of the suspension is bridge-connected to the terminal of the actuator block by soldering while making them apart from each other to some extent. Second, a terminal of a flexible printed circuit board is connected to a terminal of a wire trace of an HSA by soldering or ultrasonic bonding while making them contact with each other or making them sufficiently close to each other. If the first method is adopted, it is necessary to use a device for satisfactorily melting and solidifying solder into bridge shape to mass-produce HSAs. If the second method is adopted, the HSAs can be mass-produced despite manual work. If the terminals of the suspensions are to be connected to the respective terminals of the actuator block, the terminals of suspensions cannot be aligned due to irregularity in thickness of suspensions when the terminals of the suspensions are built up on the terminals of the actuator block. As a result, an operator disadvantageously needs to perform positioning operation or the like with respect to the terminals of the suspensions. 
         [0007]      FIG. 8  is a schematic of entire configurations of the conventional HSA and the conventional terminal connecting apparatus.  FIG. 9  is an enlarged side view of the conventional HSA and the conventional terminal connecting apparatus, viewed from an A direction shown in  FIG. 8 . 
         [0008]    As shown in  FIGS. 8 and 9 , an HSA  10  includes an actuator unit  23  that includes a plurality of suspensions  20  (eight in the example shown in  FIG. 8 ) and a plurality of actuator arms  22 , and an actuator block  30 . A magnetic head  21  is provided on a tip end of each suspension  20 . A plurality of terminals  26  (eight in the example shown in  FIG. 8 ) are provided on rear ends (lower side in  FIG. 8 ) of the actuator arms  22 . 
         [0009]    The actuator block  30  includes a pivot housing  32  that includes a pivot bearing  31  and a coil support  42  that holds a voice coil  41  fixed to a rear end (lower side in  FIG. 8 ) of the pivot housing  32 . A plurality of terminals  34  (eight in the example shown in  FIG. 8 ) is provided to be aligned on an upper surface of the pivot housing  32  (see  FIG. 4 ). 
         [0010]    A conventional terminal connecting apparatus  50   a  includes a pressure actuator  80   a  and a terminal connection chip  90 . The pressure actuator  80   a  presses the terminals  26  of the suspensions  20  against the terminals  34  (see  FIG. 4 ) of the actuator block  30 , respectively. The terminal connection chip  90  superimposes the terminals  26  on the terminals  34  and connects the terminals  26  to the terminals  34 , respectively. 
         [0011]    In the HSA  10  shown in  FIGS. 8 and 9 , if the terminals  26  of the suspensions  20  are to be connected to the terminals  34  of the actuator block  30 , then the terminals  26  are positioned relative to the respective terminals  34 , and the pressure actuator  80   a  presses the terminals  26  from above. Furthermore, the terminals  26  are connected to the terminals  34  by soldering or the like using the terminal connection chip  90 . 
         [0012]    Referring to a flowchart of  FIG. 10 , procedures of connecting the terminals  26  of the suspensions  20  to the respective terminals  34  of the actuator block  30  will be explained in detail. 
         [0013]    The HSA  10  is inserted (step S 110 ), and a suspension-position measuring processing for measuring a present position of each suspension  20  is performed (step S 120 ). The suspension-position measuring processing is intended to position the terminal  26  of each suspension  20  relative to each terminal  34  of the actuator block  30 . 
         [0014]    A suspension-position correction processing for correcting the position of the suspension  20  to a normal position is performed based on the measured position (step S 130 ). A suspension-terminal connection processing for connecting the terminal  26  of each suspension  20  to each terminal  34  of the actuator block  30  is performed based on the position of the suspension  20  corrected at the step S 130  (step S 140 ). 
         [0015]    The processing from the steps S 120  to the step S 140  is repeatedly performed by as much as the number of suspensions  20  that constitute the HSA  10 . If connection of the terminals  26  of all the suspensions  20  to the respective terminals  34  of the actuator block  30  is completed (Yes at step S 150 ), the HSA  10  is ejected (step S 160 ). 
         [0016]    As explained with reference to the flowchart of  FIG. 10 , with the conventional connecting method for the terminals  26  of the suspensions  20 , the terminal  26  of each suspension  20  is connected to each terminal  34  of the actuator block  30  while the position of the terminal  26  is measured and corrected as needed. In this case, the connection operation is performed by either operator&#39;s manual-operation or image recognition of connected portions between the terminals  26  and  34  and actuator&#39;s automatic operation. 
         [0017]    As a conventional technique related to the connection between the terminal of the suspension to the terminal of the actuator block of this type, Japanese Patent Application Laid-Open No. 2006-49751 discloses a technique for providing a backing member on an insulating layer of the terminal of each suspension. 
         [0018]    According to the technique disclosed in Japanese Patent Application Laid-Open No. 2006-49751, even if a crack occurs while a solder is to be bonded to the terminal, the backing member of the terminal is bonded to the insulating layer. Therefore, conductivity is ensured. Moreover, the terminal of a flexible printed circuit board can be soldered to the terminal of the wire trace of the suspension assembly without causing a soldering failure or the like. 
         [0019]    However, the conventional method of connecting the terminal of the suspension to that of the actuator block has the following problems. The positioning of the terminal of the suspension relative to that of the actuator block is performed either by operator&#39;s manual operation or the image recognition and actuator&#39;s automatic operation. Specifically, the terminal  26  of the suspension  20  is connected to the terminal  34  of the actuator block while the operator makes position measurement and position correction at needed. Due to this, the connection step cannot be started until the positioning of the terminals is performed. This disadvantageously increases operation time, reduces the number of produced HSAs, and thereby causes cost hike. 
       SUMMARY OF THE INVENTION 
       [0020]    It is an object of the present invention to at least partially solve the problems in the conventional technology. 
         [0021]    An apparatus according to one aspect of the present invention is for connecting terminals of a plurality of suspensions constituting a head suspension assembly including the suspensions and an actuator block with terminals of the actuator block. The apparatus includes a terminal pressing unit that collectively presses the terminals of the suspensions against the terminals of the actuator block; and a terminal connecting unit that connects the terminals of the suspensions with the terminals of the actuator block. 
         [0022]    An apparatus according to another aspect of the present invention is for connecting terminals of a plurality of suspensions constituting a head suspension assembly including the suspensions and an actuator block with terminals of the actuator block. The apparatus includes a terminal pressing unit that collectively presses the terminals of the suspensions against the terminals of the actuator block; a terminal connecting unit that connects the terminals of the suspensions with the terminals of the actuator block; and a lateral positioning unit for positioning the terminals of the suspensions and the terminals of the actuator block in a lateral direction when connecting the terminals of the suspensions with the terminals of the actuator block. 
         [0023]    A method according to still another aspect of the present invention is for manufacturing a suspension assembly including at least a plurality of suspensions and an actuator block. The method includes positioning each of the suspensions in a longitudinal direction when connecting terminals of the suspensions with terminals of the actuator block; positioning the terminals of the suspensions and the terminals of the actuator block in a lateral direction; pressing collectively the terminals of the suspensions against the terminals of the actuator block; and connecting the terminals of the suspensions with the terminals of the actuator block. 
         [0024]    The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  is a schematic of entire configurations of an HSA and a terminal connecting apparatus according to an embodiment of the present invention; 
           [0026]      FIG. 2  is an enlarged side view of the HSA and the terminal connecting apparatus, viewed from a direction A shown in  FIG. 1 ; 
           [0027]      FIG. 3  is an enlarged view of a part B shown in  FIG. 1 ; 
           [0028]      FIG. 4  is an enlarged view of a part C shown in  FIG. 1 ; 
           [0029]      FIG. 5A  is an enlarged view of a modified configuration of a pressure actuator; 
           [0030]      FIG. 5B  an enlarged view of another modified configuration of a pressure actuator; 
           [0031]      FIG. 6  is schematic for explaining longitudinal positioning; 
           [0032]      FIG. 7  is a flowchart of procedures of connection processing for terminals of suspensions; 
           [0033]      FIG. 8  is a schematic of entire configurations of a conventional HSA and a conventional terminal connecting apparatus; 
           [0034]      FIG. 9  is an enlarged side view of the conventional HSA and the conventional terminal connecting apparatus, viewed from a direction A shown in  FIG. 8 ; and 
           [0035]      FIG. 10  is a flowchart of procedures of connection processing for terminals of suspensions according to a conventional technique. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0036]    Exemplary embodiments of the present invention will be explained in detail below with reference to the accompanying drawings. It is to be noted that the present invention is not limited to the embodiments. 
         [0037]      FIG. 1  is a schematic of entire configurations of the HSA  10  and a terminal connecting apparatus  50  according to the embodiment of the present invention.  FIG. 2  is an enlarged side view of the HSA  10  and the terminal connecting apparatus  50 , viewed from the A direction shown in  FIG. 1 .  FIG. 3  is an enlarged view of a part B shown in  FIG. 1 , and  FIG. 4  is an enlarged view of a part C shown in  FIG. 1 . 
         [0038]    As shown in  FIGS. 1 and 2 , the HSA  10  includes the actuator unit  23  that includes a plurality of suspensions  20  (eight in the example shown in  FIG. 1 ) and a plurality of actuator arms  22  (five in the example shown in  FIG. 1 ), and the actuator block  30 . 
         [0039]    The suspensions  20  are provided to be aligned in a comb-like fashion, and magnetic heads  21  each for recording/reproducing data in/from a disk are provided on tip ends of the respective suspensions  20 . The actuator arms  22  are coupled to rear ends of the suspensions  20 . Moreover, rear ends of the actuator arms  22  are fixedly coupled to the actuator block  30 . 
         [0040]    The suspension  20  can be manufactured by drawing, for example, a stainless plate or aluminum and then machining the drawn stainless plate or aluminum into a predetermined shape. Furthermore, a plurality of terminals  26  (eight in the example shown in  FIG. 1 ) are provided on the rear ends (lower side in  FIG. 1 ) of the actuator arms  22 . 
         [0041]    The actuator block  30  includes the pivot housing  32  that includes the pivot bearing  31  and the coil support  42  that holds the voice coil  41  fixed to the rear end (lower side in  FIG. 1 ) of the pivot housing  32 . A plurality of terminals  34  (eight in the example shown in  FIG. 1 ) is provided to be aligned on the upper surface of the pivot housing  32  (see  FIG. 4 ). 
         [0042]    The terminal connecting apparatus  50  connects the terminal  26  provided on the actuator arm  22  of the suspension  20  to the terminal  34  provided on the pivot housing  32  as will be explained later in detail. 
         [0043]    A voice coil yoke (not shown) that constitutes, together with the voice coil  41 , a voice coil motor is arranged on a rear end (lower side in  FIG. 1 ) of the pivot housing  32 . A permanent magnet is attached inside the voice coil yoke to generate an electromagnetic field. The suspensions  20  can thereby rotate around a pivot shaft  33  of the pivot bearing  31  provided in the pivot housing  32 . 
         [0044]    A tab  24  (see  FIG. 2 ) protruding upward is provided on an upper surface of each suspension  20 , and a circular hole  25  is formed at a predetermined position on the tab  24 . The terminal connecting apparatus  50  can position the suspensions  20  in a lateral direction by moving the suspensions  20  in the lateral direction (X direction in FIG.  4 ) while holding the tab  24  of each suspension  20 . Moreover, by inserting a longitudinal positioning pin  70  into the circular hole  25  formed in the tab  24  of each suspension  20 , the terminal connecting apparatus  50  can position the suspensions in the longitudinal direction. 
         [0045]    In case of the HSA  10  shown in  FIGS. 1 and 2 , the magnetic heads  21  (eight in the example shown in  FIG. 1 ) provided on the respective suspensions  20  can reproduce/record data from/on front and rear sides of four disks. 
         [0046]    As explained, the HSA  10  is configured so that the actuator arms  22  coupled to the suspensions  20 , the actuator block  30 , and the coil support  42  including the voice coil  41  are fixedly assembled with one another. As shown in  FIG. 4 , during assembly of the suspensions  20  with the actuator block  30 , the terminal connecting apparatus  50  can connect the terminals  26  provided on the rear ends of the actuator arms  22  to the terminals  34  provided on the upper surface (upper side in  FIG. 4 ) of the pivot housing  32 , respectively. 
         [0047]    The terminal connecting apparatus  50  according to the embodiment is characterized as follows. To connect the terminals  26  of the suspensions  20  to the respective terminals  34  of the actuator block  30 , the terminals  26  of all the suspensions  20  are integrally connected to and integrally positioned relative to the respective terminals  34  of the actuator block  30  differently from the conventional technique. According to the conventional terminal connecting apparatus  50   a , the connection and positioning are performed per suspension. Furthermore, during the connection of the terminals  26  to the respective terminals  34 , it is possible to accurately and easily perform lateral (X-direction) positioning ( 1 ), longitudinal (Y-direction) positioning ( 2 ), and height-direction (Z-direction) positioning ( 3 ). 
         [0048]    The lateral (X-direction) positioning ( 1 ) is performed to correct a lateral displacement generated when the terminal  26  is connected to each terminal  34 . The longitudinal (Y-direction) positioning ( 2 ) is performed to align the terminals  26  of the suspensions  20  in the longitudinal direction using the longitudinal positioning pin  70  (see  FIG. 1 ). The height-direction (Z-direction) positioning ( 3 ) is performed to position a height position of the terminal  26  relative to the terminal  34  during the connection between the terminals  26  and  34  using a pressure pin  81  of each pressure actuator  80  (see  FIGS. 2 and 4 ). 
         [0049]    To perform these positioning operations, the terminal connecting apparatus  50  includes the pressure actuator  80 , the terminal connection chip  90 , and a lateral positioning mechanism  60  as shown in  FIGS. 1 to 3 . The pressure actuator  80  includes a plurality of pressure pins  81  (eight in the example shown in  FIG. 3 ) for pressing the terminals  26  of the suspensions  20  against the respective terminals  34  of the actuator block  30  and for positioning heights of the terminals  26  of the suspensions  20 . The terminal connection chip  90  connects the terminals  26  to the terminals  34  by soldering or the like. The lateral positioning mechanism  60  positions the terminals  26  and  34  relative to each other in the lateral direction (X direction). 
         [0050]    As shown in  FIG. 3 , the lateral positioning mechanism  60  includes fixed claws  61 , fixed support members  62  fixing the respective fixed claws  61 , moving claws  63 , fixed support members  64  fixing the respective moving claws  63 , compression spring members  67  applying predetermined elastic forces to the respective moving claws  63 , a moving support member  65  that integrally moves the fixed support members  64 , and a moving arm member  66 . In ordinary state, the moving claws  63  are pressed against the fixed claws  61  by the elastic forces of the compression spring members  67 , respectively. 
         [0051]    Namely, the moving claw  63  is configured to hold the tab  24  of each suspension  20  between the moving claw  63  and the fixed claw  61  and to integrally and freely move the suspensions  20  in the lateral direction (X direction). 
         [0052]    It is thereby possible to integrally position the terminals  26  of the suspensions  20  in the lateral direction. In the embodiment, a compression spring is used as the compression spring member. Alternatively, a plate spring or the like can be used as the compression spring member. 
         [0053]    As shown in  FIG. 3 , the pressure actuator  80  includes a plurality of pressure pins  81  (eight in the example shown in  FIG. 3 ). The pressure actuator  80  functions to press the terminals  26  from above against the terminals  34  using the respective pressure pins  81  while performing the lateral (X-direction) positioning ( 1 ), the longitudinal (Y-direction) positioning ( 2 ), and the height-direction (Z-direction) positioning ( 3 ). 
         [0054]    The pressure pins  81  are arranged at positions corresponding to positions of the terminals  26  of the suspensions  20  and the terminals  34  of the actuator block (at equal intervals). It is thereby possible to apply almost equal pressure to the terminals  26 . 
         [0055]    As a result, the terminal connecting apparatus  50  can integrally press the terminals  26  and  34 , and ensure preventing positional deviations of the connection between the terminals  26  and  34  generated when the pressure actuator  80  contacts with the terminals  26 . 
         [0056]    Moreover, as shown in  FIG. 3 , the terminal connection chip  90  functions to connect the terminals  26  of the suspensions  20  to the terminals  34  of the actuator block  30  by soldering after the terminals  26  and  34  are positioned in the lateral direction (X direction) (1), the longitudinal direction (Y direction) (2), and the height direction (Z direction) (3). 
         [0057]    Referring to  FIGS. 5A and 5B , modified configurations of the pressure actuator  80  will be explained. In a modification shown in  FIG. 5A , a pressure actuator  80   b  is configured so that a compression spring  82  is provided in the pressure pin  81 . The pressure actuator  80   b  shown in  FIG. 5A  can absorb and correct a positional deviation of the connection between the terminals  26  and  34  resulting from the thickness of the suspension  20  or the like by an elastic force of the compression spring  82  during pressing of the terminal  26  by the pressure pin  81 . It is thereby possible to improve accuracy of the positioning of the terminal  26  relative to the terminal  34 . 
         [0058]    In a modification shown in  FIG. 5B , a pressure actuator  80   c  is configured so that a pressure pin  81   a  is an elastic member. Similarly to the pressure actuator  80   b , the pressure actuator  80   c  shown in  FIG. 5B  can absorb and correct a positional deviation of the connection between the terminals  26  and  34  resulting from the thickness of the suspension  20  or the like by an elastic force of the pressure pin  81  made of the elastic material during pressing of the terminal  26  by the pressure pin  81 . It is thereby possible to improve accuracy of the positioning of the terminal  26  relative to the terminal  34 . 
         [0059]    Referring to  FIG. 6 , the longitudinal (Z-direction) positioning with respect to the suspensions  20  that constitute the HSA  10  will be explained. 
         [0060]    As shown in  FIG. 6 , even if longitudinal positional deviations occur to part of the suspensions  20  (indicated by dotted lines) among all the suspensions  20  that constitute the HSA  10 , all the suspensions  20  can be integrally positioned in the longitudinal direction by inserting the longitudinal positioning pin  70  into the circular hole  25  formed in the tab  24  of each suspension  20 . 
         [0061]    It is thereby possible to easily and accurately position the terminals  26  of the suspensions  20  relative to the terminals  34  of the actuator block  30  in the longitudinal direction. Furthermore, if the terminals  26  of the suspensions  20  are connected to the respective terminals  34  of the actuator block  30 , it is possible to ensure preventing longitudinal displacements in the connection between the terminals  26  to the terminals  34 . 
         [0062]    Referring to a flowchart of  FIG. 7 , procedures of the connection processing for connecting the terminals  26  of the suspensions  20  to the terminals  34  of the actuator block  30  will be explained. 
         [0063]    As shown in  FIG. 7 , the HSA  10  is inserted (step S 110 ). The lateral positioning mechanism  60  positions the terminal  26  of each suspension  20  in the lateral direction (step S 115 ). The longitudinal positioning pin  70  positions the terminal  26  of each suspension  20  in the longitudinal direction (step S 125 ). Specifically, the longitudinal positioning pin  70  is inserted into the circular hole  25  of the tab  24  of each suspension  20  to make an adjustment to set longitudinal positions of all the suspensions  20  equal. 
         [0064]    It is determined whether all the suspensions  20  are completed with the lateral positioning processing and the longitudinal positioning processing at the steps S 115  and S 125 , respectively (step S 135 ). If all the suspensions  20  are completed with the lateral positioning processing and the longitudinal positioning processing (Yes at step S 135 ), the processing goes to step S 145 . At the step S 145 , the pressure actuator  80  performs a terminal pressing process for pressing the terminals  26  of all the suspensions  20  against the respective terminals  34  of the actuator block  30  (step S 145 ). 
         [0065]    The terminal pressing process performed by the pressure actuator  80  enables simultaneously and sequentially connecting the terminals  26  of the suspensions  20  to the respective terminals  34  of the actuator block  30  by one operation. Furthermore, the terminals  26  can be held at predetermines positions (corresponding to the positions at which the respective terminals  34  of the actuator block  30  are arranged). 
         [0066]    The terminal connection chip  90  performs a connection processing for connecting the terminals  26  to the terminals  34  by soldering (step S 146 ). If it is determined that the terminals  26  of all the suspensions  20  are completed with the connection processing (Yes at step S 150 ), the HSA  10  is ejected (step S 160 ). 
         [0067]    As explained so far, the terminal connecting apparatus  50  according to the embodiment includes the pressure actuator  80 , the terminal connection chip  90 , and the lateral positioning mechanism  60 . The pressure actuator  80  integrally (simultaneously) pressures the terminals  26  of the suspensions  20  against the respective terminals  34  of the actuator block  30 . The terminal connection chip  90  connects the terminals  26  of the suspension  20  to the respective terminals  34  of the actuator block  30 . The lateral positioning mechanism  60  positions the terminals  26  relative to the terminals  34  in the lateral direction. Therefore, during the manufacturing of the HSA  10 , the connection operation for connecting the terminals  26  of the suspensions  20  to the terminals  34  of the actuator block can be accurately and efficiently performed. 
         [0068]    According to an experiment conducted by the inventor of the present invention, by performing the lateral, longitudinal, and height-direction positioning processes according to the embodiment, time required to position the suspensions  20  can be reduced to about 50% as compared with the conventional connection operation for connecting the terminal of each suspension to the terminal of the actuator block. 
         [0069]    Namely, the result of the experiment indicates that it is possible to improve the number of produced HSAs, reduce cost, improve product reliability, and reduce production yield according to the embodiment. 
         [0070]    In the embodiment, the suspension  20  includes the tab  24  in which the circular hole  25  into which the longitudinal positioning pin  70  is inserted. However, the circular hole  25  for the longitudinal positioning pin  70  is not always formed in the tab  24  of the suspension  20 . The circular hole  25  can be replaced by an independently-provided suction nozzle. 
         [0071]    As describe above, according to an embodiment of the present invention, the terminals of the suspensions can be simultaneously connected to the respective terminals of the actuator block by one operation in a sequential manner. It is thereby possible to reduce the operation time required for the terminal connection. Accordingly, the operation for connecting the terminals of the suspensions to the respective terminals of the actuator block can be accurately and efficiently performed. It is thereby possible to contribute to improvement of the number of produced HSAs and cost reduction. 
         [0072]    Furthermore, according to an embodiment of the present invention, it is possible to integrally and accurately position the terminals of the suspensions in the height direction and the lateral direction. 
         [0073]    Moreover, according to an embodiment of the present invention, during the connection of the terminals of the suspensions to the respective terminals of the actuator block, it is possible to ensure preventing the connection deviations among the terminals generated when the terminal pressing unit contacts with the terminals (positional deviations during pressing by the terminal pressing unit). 
         [0074]    Furthermore, according to an embodiment of the present invention, during the connection of the terminals of the suspensions to the respective terminals of the actuator block, it is possible to easily and accurately position the terminals of the suspensions in the longitudinal direction. 
         [0075]    Moreover, according to an embodiment of the present invention, the connection of the terminals of the suspensions to the respective terminals of the actuator block can be performed simultaneously and sequentially by one operation. It is thereby possible to reduce the operation time for the terminal connection processing. Accordingly, it is possible to accurately and efficiently perform the operation for connecting the terminals of the suspensions to the respective terminals of the actuator block. It is, therefore, possible to contribute to improvement of the number of produced HSAs and cost reduction. 
         [0076]    Although the invention has been described with respect to a specific embodiment for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.