A hard disk drive flexure assembly includes a base layer, a conductive layer, a plurality of electrical pads over the conductive layer, and a sidewall layer including sidewalls on each side of and extending higher than a corresponding electrical pad. Pre-solder bumps are formed between the sidewalls and over each pad. Use of sidewalls prevents the pre-solder bumps from undesirably bridging to an adjacent electrical pad and forming a short circuit, which might otherwise cause head-gimbal assembly (HGA) manufacturing failures and consequent increased cost. These techniques are especially relevant with narrow, high-density, small pitch electrical pads.

A suspension for a disk drive includes a plate member having a first surface, a second surface opposite to the first surface, a first penetration portion penetrating the first surface and the second surface, and a second penetration portion spaced from the first penetration portion and penetrating the first surface and the second surface, an actuator provided on the second surface and having an electrode located in the first penetration portion, and a flexure having an electrode connection portion connected to the electrode. The electrode connection portion includes a first region and a second region having a thickness smaller than a thickness of the first region, and the second region overlaps the second penetration portion.

A method of manufacturing a head gimbal assembly includes a head connecting step which a thermally assisted magnetic head is connected to a suspension. The head connecting step includes a solder ball arrangement step which only one solder ball is arranged so that a laser diode of the thermally assisted magnetic head is connected with a flexure of the suspension, in an assembly structure which a slider of the thermally assisted magnetic head is adhered to the suspension. The solder ball arrangement step is performed using a connecting ball, as the solder ball, having a size larger than a wiring gap and being in unmelted-solid condition. The head connecting step includes a heat step which an electrode surface of the laser diode is heated.

A flexure includes a metal base, a base insulation layer formed on the metal base, a terminal formed on the base insulation layer, a conductor portion electrically conductive to the terminal and an detouring extending portion formed on the conductor portion. The conductor portion includes a conductor and a cover layer covering the conductor. A conductive adhesive is supplied to the terminal. The detouring extending portion is formed in a longitudinal middle of the conductor portion and extends from the side surface of the conductor portion in a direction intersecting the length direction of the conductor portion along the base insulation layer.

Methods of critical dimension (CD) uniformity control for magnetic head devices are disclosed. In some embodiments, a method can include providing a film stack, the film stack including a substrate, a magnetoresistive (MR) sensor layer, and a hard mask layer, patterning the hard mask layer using a first mask that defines critical shape patterns other than the CD, forming a mandrel pattern using a second mask that defines the CD, and forming a sidewall spacer pattern on sidewalls of the mandrel pattern, and removing the mandrel pattern.

Methods of critical dimension (CD) uniformity control for magnetic head devices are disclosed. In some embodiments, a method can include providing a film stack, the film stack including a substrate, a magnetoresistive (MR) sensor layer, and a hard mask layer, patterning the hard mask layer using a first mask that defines critical shape patterns other than the CD, forming a mandrel pattern using a second mask that defines the CD, and forming a sidewall spacer pattern on sidewalls of the mandrel pattern, and removing the mandrel pattern.

A suspension is described. The suspension includes a base plate and a load beam coupled to the base plate. The base plate includes a distal elongated element and a proximal elongated element. The distal elongated element includes at least one non-straight baseplate edge and the proximal elongated element includes at least one non-straight baseplate edge. The load beam includes a first mounting shelf and a second mounting shelf. The load beam is coupled to the base plate such that the first mounting shelf is exposed adjacent to the distal elongated element, and the second mounting shelf is exposed adjacent to the proximal elongated element. The first and second mounting shelves are configured to receive an actuator, such that an edge of the actuator and the at least one non-straight baseplate edge forms a gap.

According to one embodiment, a suspension assembly includes a support plate, a wiring member disposed on the support plate, and a head supported on the support plate through the wiring member. The wiring member includes a distal end portion electrically connected to the head, a connection end portion extending outside the support plate, and a plurality of wirings extending between the distal end portion and the connection end portion. The connection end portion includes an opening with predetermined length and width and thirteen or more connection terminals disposed in the opening and arranged at intervals in a direction of the length. A percentage of an area of the opening occupied by areas of the thirteen or more connection terminals is 40% to 65% inclusive.

According to one embodiment, a suspension assembly includes a support plate, a trace member on the support plate and a drive element mounted on the trace member. The trace member includes a metal plate, and a multilayered member on the metal plate. The multilayered member includes a first insulating layer, a conductive layer stacked on the first insulating layer, a second insulating layer stacked on the conductive layer. The multilayered member includes a mount portion on which the drive element is mounted, and a branching portion arranged along the mount portion with a gap therebetween. At least one portion of the branching portion is formed into a thin portion having a thickness less than other portions of the multilayered member.

An adhesive reactive to ultraviolet rays is applied to an actuator mounting portion of a suspension. An electrical conducting material is applied to a conductor and the like of the actuator mounting portion. When the adhesive is irradiated with ultraviolet rays, the viscosity of the adhesive is increased. A piezoelectric element is placed on the adhesive the viscosity of which is increased. Thereafter, the adhesive and the electrical conducting material are heated, whereby the adhesive and the electrical conducting material are cured.