Method of assembling voice coil in an actuator assembly of a hard disk drive

A disk drive, comprising:

• an actuator arm rotating about an axis, said actuator arm having a distal end;
• a voice coil member having a voice coil, said voice coil member molded into said distal end;
• inner and outer bobbins made of an insertion-molding material, formed when said voice coil member is molded into said distal end, and positioned respectively at inner and outer sides of said voice coil member;
• said inner bobbin having at least one hole formed at each round corner of said inner bobbin;
• said outer bobbin formed on an entire circumferential outer side of said voice coil without covering a top surface of said voice coil, having a portion fixing said voice coil member to a side wall of said distal end, said portion of said outer bobbin having the same height as said voice coil;
• and
• an elongated portion formed on said distal end, extending towards said inner bobbin across a bottom of said portion of said outer bobbin, with an extreme portion of said elongated portion protruding between said coil and said inner bobbin and fixing said voice coil member to said distal end of said actuator arm.

An actuator assembly, comprising:

• an actuator arm having a distal end;
• a voice coil member having a voice coil, molded into and fixed to said distal end;
• an inner bobbin made of a first molding material and fixedly attached to a circumferential inner side of said voice coil member;
• a plurality of holes formed at round corners of said inner bobbin other than sides of said inner bobbin during filling inside of said voice coil member with said first molding material;
• an outer bobbin made of a second molding material and formed on an entire circumferential outer side of said voice coil when said voice coil member is molded into and fixed to said distal end;
• said outer bobbin having a portion disposed between said voice coil member and said distal end, fixing said voice coil member to said distal end when said outer bobbin is formed, said portion of said outer bobbin having the same height as said voice coil;
• a protrusion extended from said distal end and disposed on both bottom sides of said portion of said outer bobbin and said voice coil member, supporting said voice coil member;
• and
• a bending portion formed on an end of said protrusion and inserted between said voice coil member and said inner bobbin.

An actuator assembly in a disk drive, comprising

• an actuator arm having a distal end;
• a voice coil defining a top coil surface, a bottom coil surface substantially parallel to and spaced-apart from said top coil surface by a first height, an inner side, an outer side spaced-apart from said inner side, and an inner space surrounded by said inner side, said top coil surface and said bottom coil surface disposed between said inner side and said outer side;
• an inner bobbin formed within said inner space of said voice coil, contacting said inner side of said voice coil, having a second height substantially same as said first height of said voice coil;
• and
• an outer bobbin surrounding an entire circumferential surface of said outer side of said voice coil without contacting said top coil surface of said voice coil, having a top bobbin surface and a bottom bobbin surface both substantially parallel to and spaced-apart from each other by a third height substantially same as said first height of said voice coil, having a portion disposed between said voice coil and said distal end of said actuator arm with an extremity of said portion extending between said voice coil and said inter bobbin, to attach said voice coil to said distal end of said actuator arm, said portion having said third height.

An actuator assembly in a disk drive, comprising:

• an actuator arm having a distal end;
• a voice coil defining a top coil surface, a bottom coil surface spaced-apart from said top surface by a first height, an inner side, an outer side spaced-apart from said inner side, and an inner space surrounded by said inner side and filled with an inner bobbin having a second height;
• and
• an outer bobbin surrounding said outer side of said voice coil, having a top bobbin surface and a bottom bobbin surface parallel to and spaced-apart from said top bobbin surface by a third height substantially same as said first height of said voice coil, having a portion disposed between said voice coil and said distal end of said actuator arm with an extremity of said portion extending between said voice coil and said inter bobbin, to attach said voice coil to said distal end of said actuator arm without covering said top coil surface of said voice coil, said portion having said third height.