Patent ID: 7673381

Claim:
A method of manufacturing a head suspension that comprises a base to be attached to a carriage of a hard disk drive and turned around a spindle of the carriage, a load beam including a rigid part and a resilient part non-integral to the rigid part and configured to apply load onto a head that is arranged at a front end of the load beam in write and read data to and from a disk arranged in the hard disk drive, and a flexure attached to the load beam, supporting the head, and having read/write wiring patterns connected to the head, the method including: forming a flat plate framework for formation of the rigid part wherein the rigid part in finished form includes: a base end portion, to which the resilient part is to be attached, and a front end portion extending from the base end portion and having the front end of the load beam at a distal end thereof; said front end portion having a front end flat portion with front end side edges opposed in a widthwise direction of the rigid part and extending substantially longitudinally from said front end toward said base end portion; said base end portion having a width which increases with increasing distance from a junction of said base end portion and said front end portion such that said base end portion has a base end flat portion with base end side edges that define a greater angle of inclination with respect to a center-line of said rigid part than said front end side edges; and said front end side edges being connected to said base end side edges by inflection curved edges at said junction; said forming of said flat plate framework including providing a rigid part flat portion corresponding to said front end flat portion and said base end flat portion and defining a flat portion plane in which lay said inflection curved edges, and providing rail formation margins extending flat outward in said flat portion plane from said base end side edges, said front end side edges, and said inflection curved edges, and portions of said rail formation margins extending outward from said inflection curved edges forming longitudinally curved rail formation margins, said rail formation margins being configured to be formed into rails; and forming deformable parts in said longitudinally curved rail formation margins at positions adjacent each of said inflection curved edges, said deformable parts being rendered deformable by weakening said longitudinally curved rail formation margins adjacent said inflection curved edges in comparison to other portions of said rail formation margins; and forming the rails by bending the formation margins to form bent portions rising out of said flat portion plane and deform said deformable parts into curved rail portions.