Claims
- 1. A method for making an actuator assembly, comprising:
a. Forming a first structural member from composite fiber material; b. Forming a second structural member from composite fiber material; c. Forming a flexure member from flexible material; d. Applying adhesive to said structural members; e. Combining said structural members and said flexure member, with said flexure member disposed between said first and second structural members.
- 2. The method of claim 1, further comprising forming registration means in each of said structural members and said flexure member.
- 3. The method of claim 2, wherein the step of combining said structural members and said flexure member further comprises aligning said registration means for each of said structural members and said flexure member.
- 4. The method of claim 1, wherein said step of forming a first structural member comprises forming a plurality of structural members.
- 5. The method of claim 1, wherein said step of forming a second structural member comprises forming a plurality of structural members.
- 6. The method of claim 1, wherein said step of forming a flexure member comprises forming a plurality of flexure members.
- 7. The method of claim 1, wherein said step of forming said first structural member comprises forming a forward portion and a rearward portion.
- 8. The method of claim 1, wherein said step of forming said second structural member comprises forming a forward portion and a rearward portion.
- 9. The method of claim 1, wherein said step of forming said flexure member comprises forming a forward portion and a rearward portion.
- 10. The method of claim 1, wherein the composite fiber material used to form said structural members includes carbon fiber.
- 11. The method of claim 2, wherein the carbon fibers have a diameter of approximately 0.002 inches.
- 12. The method of claim 1, wherein the fibers in said composite fiber material are selected from one or more of the following materials: glass, magnesium, boron, beryllium, Kevlar or ceramic.
- 13. The method of claim 1, wherein said forming is cutting.
- 14. The method of claim 13, wherein said cutting is performed by a water jet.
- 15. The method of claim 1, further comprising placing the combination of said structural members and said flexure member under temperature and pressure to set said adhesive and bond said structural members and said flexure member into a laminated actuator assembly.
- 16. The method of claim 1, wherein said second step of combining comprises placing said flexure member between said first and second structural members.
- 17. The method of claim 1, wherein said adhesive is applied using silk screen techniques.
- 18. The method of claim 1, wherein said act of applying adhesive to said structural members comprises applying adhesive to all structural members.
- 19. The method of claim 3, further comprising placing said structural members and said flexure member in a fixture having complementary registration elements that align with and receive said registration members associated with said structural members and said flexure member.
- 20. The method of claim 19, wherein said fixture comprises an upper and lower portion and a stop means to set the spacing between said upper and lower portions.
- 21. The method of claim 1, wherein said adhesive is applied by spraying.
- 22. The method of claim 1, wherein said step of applying adhesive comprises applying a film of adhesive to said structural members.
- 23. The method of claim 1, wherein said steps of forming said first and second structural members comprise combining a plurality of layers of composite fiber material.
- 24. The method of claim 23, wherein said plurality of layers of composite fiber material is eight.
- 25. The method of claim 23, wherein the step of forming said structural members further comprises orienting the fibers within each layer to optimize the strength and stiffness of said structural members.
- 26. The method of claim 24, wherein the fibers in said layers are oriented relative to the longitudinal axis of said first and second structural members at zero degrees, zero degrees, plus 29 degrees, minus 29 degrees, minus 29 degrees, plus 29 degrees, zero degrees and zero degrees.
- 27. The method of claim 1, wherein said steps of forming said first and second structural members further comprise forming beam elements within said structural members.
- 28. The method of claim 25, wherein a portion of the fibers forming said first and second structural elements are substantially parallel to at least some of said beam elements.
- 29. The method of claim 1, further comprising forming a spacer member from non-structural material and positioning said spacer member in a co-planar relationship with said flexure member prior to combining said flexure member with said structural members.
- 30. The method of claim 29, wherein said step of forming a spacer member comprises forming a plurality of spacer members.
- 31. The method of claim 29, further comprising forming registration means in each of said structural members, said flexure member and said spacer member.
- 32. The method of claim 29, wherein said adhesive is applied using silk screen techniques.
- 33. The method of claim 29, wherein said act of applying adhesive to said structural members comprises applying adhesive to all structural members.
- 34. The method of claim 29, wherein said adhesive is applied by spraying.
- 35. The method of claim 29, wherein said step of applying adhesive comprises applying a film of adhesive to said structural members.
- 36. A method for making an actuator assembly, comprising:
a. forming a plurality of first structural members; b. forming a plurality of second structural members; c. forming a plurality of flexure members; d. forming a plurality of spacer members; e. applying adhesive to at least one of said first and second plurality of structural members; f. combining said first and second plurality of structural members, said plurality of flexure members and said plurality of spacer members in a fixture; g. applying pressure to the fixture to compress the plurality of first and second structural members, plurality of flexure members and plurality of spacer members to a desired thickness; and h. heating said combination to set said adhesive and bond said plurality of first and second structural members, plurality of flexure members and plurality of spacer members.
- 37. The method of claim 36, wherein said step of forming a first plurality of structural members comprises forming structural members with a front and rear portion, and said step of forming a plurality of second structural members comprises forming structural members with a front and rear portion.
- 38. The method of claim 36, wherein said step of applying adhesive comprises placing a silk screen over said at least one of said plurality of structural members and applying adhesive through said silk screen.
- 39. The method of claim 36, wherein said adhesive is applied by a roller.
- 40. The method of claim 36, wherein said adhesive is applied by spraying.
- 41. The method of claim 36, wherein said step of forming first and second structural members comprises combining a plurality of individual fiber composite layers.
- 42. The method of claim 36, wherein said steps of forming a plurality of first and second structural members comprises forming each of said structural members from a plurality of layers of composite fiber material.
- 43. The method of claim 42, wherein said step of forming said first and second structural members comprises cutting said layers into desired shapes.
- 44. The method of claim 42, wherein said fibers are selected from the group comprising carbon, glass, magnesium, boron, beryllium, ceramic and kevlar.
- 45. The method of claim 36, wherein said steps of forming said first and second structural members comprise combining a plurality of layers of composite fiber material.
- 46. The method of claim 45, wherein said plurality of layers of composite fiber material is eight.
- 47. The method of claim 45, wherein the step of forming said structural members further comprises orienting the fibers within each layer to optimize the strength and stiffness of said structural members.
- 48. The method of claim 47, wherein the fibers in said layers are oriented relative to the longitudinal axis of said first and second structural members at zero degrees, zero degrees, plus 29 degrees, minus 29 degrees, minus 29 degrees, plus 29 degrees, zero degrees and zero degrees.
- 49. The method of claim 36, wherein said steps of forming said first and second structural members further comprise forming beam elements within said structural members.
- 50. The method of claim 49, wherein said first and second structural elements comprise layers of composite fiber material and said fibers within at least some of said layers are substantially parallel to at least some of said beam elements.
- 51. The method of claim 36, further comprising creating multiple individual actuator arm assemblies by separating the individual arm assemblies from the cured and bonded planar panels.
- 52. A method for making an actuator assembly, comprising:
a. forming a plurality of first structural members in a planar element panel; b. forming a plurality of second structural members in a planar element panel; c. forming a plurality of flexure members in a planar element panel; d. applying adhesive to at least one of said first and second plurality of structural members in said planar element panel; e. combining said first and second plurality of structural members in said planar element panels and said plurality of flexure members in said planar panel in a fixture; f. applying pressure to the fixture to compress the plurality of first and second structural members in said planar element panels and said plurality of flexure members in said planar panels to a desired thickness; and g. heating said combination to cure said adhesive and bond said plurality of first and second structural members in said planar element panels and said plurality of flexure members in said planar panels.
- 53. The method of claim 52, further comprising forming a plurality of spacer members in a planar panel and combining said panel of spacer members with said plurality of structural members and said plurality of flexure members.
- 54. The method of claim 53, further comprising forming registration means in said planar element panels of first structural members, second structural members, flexure members and spacer members.
- 55. The method of claim 52, wherein said step of forming a first plurality of structural members comprises forming structural members with a front and rear portion, and said step of forming a plurality of second structural members comprises forming structural members with a front and rear portion.
- 56. The method of claim 52, wherein said step of applying adhesive comprises placing a silk screen over said at least one of said plurality of structural members and applying adhesive through said silk screen.
- 57. The method of claim 52, wherein said adhesive is applied by a roller.
- 58. The method of claim 52, wherein said adhesive is applied by spraying.
- 59. The method of claim 52, wherein said step of forming first and second structural members comprises combining a plurality of individual fiber composite layers.
- 60. The method of claim 59, wherein said step of forming said first and second structural members comprises cutting said layers into desired shapes.
- 61. The method of claim 60, wherein said fibers are selected from the group comprising carbon, glass, magnesium, boron, beryllium, ceramic and kevlar.
- 62. The method of claim 53, further comprising creating multiple individual actuator arm assemblies by separating the individual arm assemblies from the cured and bonded planar panels.
- 63. The method of claim 52, wherein said steps of forming said first and second structural members comprise combining a plurality of layers of composite fiber material.
- 64. The method of claim 63, wherein said plurality of layers of composite fiber material is eight.
- 65. The method of claim 63, wherein the step of forming said structural members further comprises orienting the fibers within each layer to optimize the strength and stiffness of said structural members.
- 66. The method of claim 64, wherein the fibers in said layers are oriented relative to the longitudinal axis of said first and second structural members at zero degrees, zero degrees, plus 29 degrees, minus 29 degrees, minus 29 degrees, plus 29 degrees, zero degrees and zero degrees.
- 67. The method of claim 52, wherein said steps of forming said first and second structural members further comprise forming beam elements within said structural members.
- 68. The method of claim 65, wherein a portion of the fibers forming said first and second structural elements are substantially parallel to at least some of said beam elements.
- 69. A method for making an actuator assembly, comprising:
a. forming a plurality of arrays of first structural elements from composite fiber material; b. forming a plurality of arrays of second structural elements from composite fiber material; c. forming a plurality of arrays of flexure elements from flexible material; d. forming a plurality of arrays of spacer elements from non-structural material; e. combining said plurality of arrays of first structural elements to form an array of first planar elements; f. combining a plurality of arrays of second structural elements to form an array of second planar elements; g. applying adhesive to said first and second arrays of planar elements; and h. combining an array of first and second planar elements, an array of flexure elements and an array of spacer elements to form an actuator assembly array. i. creating multiple individual actuator arm assemblies by separating the individual arm assemblies from the cured and bonded planar panels.
- 70. The method of claim 69, further comprising forming registration elements in each of said first and second arrays of planar elements, said array of flexure elements and said array of spacer elements.
- 71. The method of claim 69, wherein each step of combining further comprises aligning said registration elements.
- 72. The method of claim 69, wherein said first structural elements comprise a forward portion and a rearward portion.
- 73. The method of claim 69, wherein said second structural elements comprise a forward portion and a rearward portion.
- 74. The method of claim 69, wherein said flexure members comprise a forward portion and a rearward portion.
- 75. The method of claim 69, wherein said composite fiber material comprises carbon fiber.
- 76. The method of claim 69, wherein said step of forming is cutting.
- 77. The method of claim 76, wherein said cutting is performed with a water jet.
- 78. The method of claim 69, wherein said step of combining an array of first and second planar elements, an array of flexure elements and an array of spacer elements comprises placing said arrays of planar elements, flexure elements and spacer elements under elevated temperature and pressure.
- 79. The method of claim 78, wherein said pressure is in excess of approximately 50 pounds per square inch and said temperature is in excess of approximately 350 degrees Fahrenheit.
- 80. The method of claim 69, wherein said step of forming a plurality of arrays of first and second structural members comprises combining a plurality of layers of composite fiber material.
- 81. The method of claim 80, further comprising cutting said layers of composite fiber material into discrete shapes.
- 82. The method of claim 81, wherein said discrete shapes include beam elements.
- 83. The method of claim 80, wherein step of forming a plurality of arrays of first and second structural members comprises aligning fibers parallel to some beam elements.
- 84. The method of claim 80, wherein said step of forming a plurality of arrays of first and second structural elements comprises combining at least eight layers of composite fiber material.
- 85. The method of claim 83, wherein said step of forming a plurality of arrays of first and second structural elements comprises orienting said fibers relative to the longitudinal axis of said structural members at zero degrees, zero degrees, plus 29 degrees, minus 29 degrees, minus 29 degrees, plus 29 degrees, zero degrees and zero degrees respectively for said eight layers.
- 86. The method of claim 85, wherein said fibers are carbon.
- 87. The method of claim 86, wherein said fibers are approximately 0.002 inches in diameter.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to U.S. patent application Ser. No. 09/557,284, filed Apr. 24, 2000, entitled “Tilt Focus Method and Mechanism for an Optical Drive,” which is incorporated herein by reference in its entirety.