BACKGROUND

Both external and internal disk drives are typically associated with at least one disk drive status light, often used to provide an indication of disk drive read/write activity. In some disk drives, an external electrical connector couples the disk drive to a separate disk drive status light incorporated into a computer case or external disk drive case. The disk drive may then drive the status light during operation.

In other disk drives, the disk drive status light is formed integrally with the disk drive, and light emitted by the status light may be guided outside an external case holding the disk drive {e.g., via one or more holes in the external case).

Unfortunately, when the disk drive status light is a component of the disk drive, the location of the status light may not be ideal for viewing by a user, due to space and configuration constraints on the disk drive. As a result, relatively complex light guides may be formed between the disk drive status light and a lens visible to the user. Since the lens is typically coupled to an external case of the disk drive, as the disk drive moves relative to the external case, stresses may be introduced into the physical components of the light guide system coupling the disk drive status light to the lens.

There is therefore a need for an improved light guide system between a disk drive status light and a lens.

SUMMARY

One aspect of the present disclosure includes an external disk drive having an external case, a disk drive positioned within the external case including a light source configured to emit light indicative of a disk drive status, a first light pipe mechanically coupled to the disk drive and positioned and configured to directly receive and guide light emitted by the light source, and a second light pipe mechanically coupled to the external case and separated from the first light pipe, wherein the second light pipe is positioned and configured to receive and to guide light from the first light pipe to a status lens visible outside the external case. In one embodiment, such an external disk drive includes a printed circuit board, and the first light pipe is mechanically coupled to the printed circuit board via a snap fit coupling proximate the light source, such as a light emitting diode (LED).

Another aspect of the disclosure provides a disk drive status light guide system for a disk drive, which includes a light source configured to emit light indicative of a disk drive status. Such a light guide system includes a first light pipe configured and dimensioned to mechanically couple to the disk drive and configured to directly receive and guide light emitted by the light source and a second light pipe separate from the first light pipe, the second light pipe configured to receive and guide light from the first light pipe to a status lens visible to a user. In an embodiment, the first light pipe and the second light pipe may include polycarbonate. Another aspect of the present disclosure includes a method of manufacturing an external disk drive. Such a method includes steps for providing an external case and a disk drive, the disk drive including a light source configured to emit light indicative of a disk drive status; providing a first light pipe and a second light pipe; coupling the first light pipe to the disk drive such that the first light pipe is positioned to directly receive and guide light emitted by the light source; coupling the second light pipe to the external case; and positioning the disk drive within the external case such that the second light pipe is separated from the first light pipe and positioned to receive and guide light from the first light pipe to a status lens. Another aspect of the present disclosure includes a light guide system for an electronic storage device, wherein the electronic storage device includes a light source configured to emit light indicative of a storage device status. Such a light guide system includes a first light pipe configured and dimensioned to mechanically couple to the electronic storage device and configured to directly receive and guide light emitted by the light source and a second light pipe separate from the first light pipe, the second light pipe configured to receive and guide light from the first light pipe to a status lens visible to a user. BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 A is a perspective view of an external disk drive, according to one illustrated embodiment.

Figure 1 B is a perspective view of the external disk drive of Figure 1 A with an external case removed to show first and second light pipes, according to one illustrated embodiment.

Figure 1 C is a perspective view of the external disk drive of Figure 1 A with the external case and the second light pipe removed, according to one illustrated embodiment. Figure 2 is a perspective view illustrating a printed circuit board, first light pipe and second light pipe of the external disk drive of Figure 1 A, according to one illustrated embodiment.

Figure 3 is a top view illustrating the printed circuit board, the first light pipe and the second light pipe of Figure 2, according to one illustrated embodiment. Figure 4 is a perspective, magnified view of the first light pipe and the second light pipe of the external disk drive of Figure 1 A, according to one illustrated embodiment.

Figure 5 is a side view of the first light pipe and the second light pipe of Figure 4 as well as a light source, according to one illustrated embodiment. Figure 6 is an illustration of a light path defined by the first and second light pipes of Figure 4, according to one illustrated embodiment.

Figure 7A is a perspective view of the first light pipe of Figure 4, according to one illustrated embodiment.

Figure 7B is a side view of the first light pipe of Figure 4 as well as a light source, according to one illustrated embodiment.

Figure 7C is a bottom view of the first light pipe and the light source of Figure 7B, according to one illustrated embodiment.

Figure 7D is a top view of the first light pipe of Figure 4, according to one illustrated embodiment. Figure 8A is a front, perspective view of the second light pipe of Figure 4, according to one illustrated embodiment. Figure 8B is a front view of the second light pipe of Figure 4, according to one illustrated embodiment.

Figure 8C is a rear, perspective view of the second light pipe of Figure 4, according to one illustrated embodiment. Figure 8D is a rear view of the second light pipe of Figure 4, according to one illustrated embodiment.

Figure 8E is a side view of the second light pipe of Figure 4, according to one illustrated embodiment.

Figure 9 illustrates a flow chart for a method of manufacturing an external disk drive, according to one illustrated embodiment.

DETAILED DESCRIPTION

Referring to Figures 1A, 1 B and 1 C, an external disk drive 100 is illustrated, according to one embodiment. The external disk drive 100 comprises an external case 102 and a disk drive 104 positioned within the external case 102, the disk drive 104 including a light source (see, e.g., the light source 1 18 in Figure 5) configured to emit light indicative of a disk drive status. Figures 1 B and 1 C illustrate the external disk drive 100 with the external case 102 removed to better illustrate the disk drive 104 and other components. A first light pipe 106 is mechanically coupled to the disk drive 104 and positioned and configured to directly receive and guide light emitted by the light source. A second light pipe 108 (illustrated in Figure 1 B, but removed in Figure 1 C) is mechanically coupled to the external case 102 and separated from the first light pipe 106. The second light pipe 108 may be positioned and configured to receive and guide light from the first light pipe 106 to a status lens 110 visible outside the external case 102. The external disk drive 100 may comprise any of a variety of external storage devices configured to communicate with a personal computer. For example, the external disk drive 100 may comprise an external drive having a Universal Serial Bus (USB), FireWire or other serial interface, a networked disk drive providing file server capabilities, a personal media device having an internal disk drive {e.g., an mp3 player), or a cellular phone having an internal disk drive. In addition to the disk drive 104, the external disk drive 100 may include various controllers and/or processors configured to perform computing tasks. The external case 102 may comprise any of a variety of cases configured to surround and protect the disk drive 104. As illustrated, the external case 102 may be shaped similarly to and tightly enclose the disk drive 104. However, in other embodiments, the external case 102 may have any shape and size and may incorporate a number of other electronic components in addition to the disk drive 104. The external case 102 may also include one or more holes 1 12 to accommodate interconnections with the disk drive 104 (e.g., to enable communication with and/or powering of the disk drive 104). As illustrated in Figure 1 A, the hole 1 12 through the external case 102 may be aligned with a USB interface of the disk drive 104, and may be dimensioned to receive a USB connector. The external case 102 may further include a hole 1 14 configured and dimensioned to receive the status lens 1 10, thus providing a visible indication of disk drive status to the user.

The external case 102 may comprise any of a variety of materials. In one embodiment, the external case 102 comprises a plurality of molded plastic pieces. The external case 102 may be modular, such that the same molded plastic pieces may be used to form a variety of differently shaped and sized external cases. In another embodiment, the external case 102 may comprise metal, such as stainless steel or aluminum. The disk drive 104 comprises a magnetic disk drive. However, the structures and methods described herein may also be applied to and/or implemented in other disk drives, including, e.g., optical and magneto-optical disk drives. Indeed, in other embodiments, the disk drive 104 may be replaced by other electronic storage devices {e.g., solid state devices) positioned within an external case. The disk drive 104 includes a light source (see ,e.g., the light source 1 18 of

Figure 5) configured to emit light indicative of a disk drive status. The disk drive status may be associated with a variety of different disk drive characteristics. In one embodiment, the disk drive status corresponds to disk drive activity. For example, when the disk drive 104 is accessing data (i.e., reading data from or writing data to a disk), the light source may be configured to emit light. In other embodiments, the disk drive status may correspond to track seeking, external communications, disk drive processor usage, or other disk drive characteristics. In still other embodiments, one or more light sources may be employed, with different colors and/or intensities of light indicative of different disk drive status measures. For example, writing data to a disk and reading data from a disk may be associated with different colors or light intensities.

The light source may comprise any of a variety of light sources and may be positioned in different locations on the disk drive 104. In one embodiment, the light source comprises a light emitting diode (LED), such as a low profile and low power surface mounted LED. In another embodiment, a laser source may be used. The light source may also be driven by a variety of different circuitry in the disk drive 104, depending upon the type of light source and the disk drive status associated with the light source. In one embodiment, a disk drive controller may control the light source based upon disk drive activity.

In one embodiment, the external disk drive 100 further includes a light guide system configured to receive light emitted by the light source, the light guide system comprising a first light pipe 106 and a second light pipe 108 (illustrated in Figure 1 B). The first light pipe 106 may be mechanically coupled to the disk drive 104, and positioned and configured to directly receive and guide light emitted by the light source. The first light pipe 106 may be mechanically coupled to the disk drive 104 in a variety of ways. In one embodiment, the first light pipe 106 may be mechanically coupled to a PCB of the disk drive 104 via a snap fit coupling proximate the light source. For example, the PCB may include one or more holes near the light source, and the first light pipe 106 may include at least one pair of outwardly facing prongs that may be inserted through the holes to fix the first light pipe 106 relative to the PCB. In other embodiments, the first light pipe 106 may be mechanically coupled via a friction fit, adhesives, screws or other structures. In still other embodiments, the first light pipe 106 may be formed integrally with the disk drive 104.

The first light pipe 106 may be positioned to directly receive and guide light emitted by the light source. In one embodiment, a first optical quality surface of the first light pipe 106 is proximate to and faces the light source, and the light entering the first optical quality surface may be guided through the first light pipe 106 to a second optical quality surface where the light may exit the first light pipe 106. The first light pipe 106 may receive and guide only a small percentage of the light emitted by the light source, although, in some embodiments, a substantial majority of the light emitted by the light source enters the first light pipe 106. The first light pipe 106 may be formed from a variety of materials configured to conduct light therethrough. In one embodiment, the first light pipe 106 may comprise polycarbonate. In another embodiment, the first light pipe 106 may comprise an acrylic material. In other embodiments, the first light pipe 106 may comprise glass, glass fibers or other materials.

The second light pipe 108 may be mechanically coupled to the external case 102 and separated from the first light pipe 106. In one embodiment, the second light pipe 108 is further positioned and configured to receive and guide light from the first light pipe 106 to a status lens 1 10 visible outside the external case 102. The second light pipe 108 may be mechanically coupled to the external case 102 in a variety of ways. In one embodiment, the second light pipe 108 is ultrasonically welded to the external case 102. In another embodiment, the second light pipe 108 may be adhesively coupled to the external case 102. In yet another embodiment, a friction fit may be formed between the hole 1 14 through the external case 102 and an elongate portion of the second light pipe 108 defining the status lens 1 10. In other embodiments, the second light pipe 108 may be mechanically coupled to the external case 102 via a snap fit, a friction fit, screws or other structures. In still other embodiments, the second light pipe 108 may be formed integrally with the external case 102. The second light pipe 108 may be positioned to receive and guide light from the first light pipe 106 to a status lens 1 10. In one embodiment, a third optical quality surface of the second light pipe 108 is proximate to and faces the second optical quality surface of the first light pipe 106. The light entering the second light pipe 108 via the third optical quality surface may then be guided to a status lens 1 10 (which may comprise a separate component or may be integrated with the second light pipe 108). The second light pipe 108 may receive and guide only a small percentage of the light exiting the second optical quality surface, although, in some embodiments, a substantial majority of the light exiting the second optical quality surface enters the second light pipe 108. The status lens 1 10 simply comprises a surface configured to allow light to pass therethrough, such that a user might view the light. In some embodiments, the status lens 1 10 may be defined by a surface of the second light pipe 108. In other embodiments, the status lens 110 may be formed separately. For example, the status lens 1 10 may comprise a surface of a third light pipe (not shown) configured to receive light from the second light pipe 108.

The second light pipe 108 may be formed from a variety of materials designed to conduct light therethrough. In some embodiments, the first and second light pipes 106, 108 may be made from the same materials, although, in other embodiments, different materials may be used. In one embodiment, the second light pipe 108 may comprise polycarbonate. In another embodiment, the second light pipe 108 may comprise an acrylic material. In other embodiments, the second light pipe 108 may comprise glass, glass fibers or other materials. Although described in the context of an external disk drive 100, the light guide system described herein may also be used with other media storage devices (including, e.g., internal electronic storage devices). In addition, although described as including just two light pipes, other light guide systems may include more than two light pipes in accordance with some embodiments. As illustrated in Figures 1 B and 1 C, the external disk drive 100 may further include a soft disk drive suspension 115. The soft disk drive suspension 1 15 includes four corner pieces 115a-d and enables the disk drive 104 to move within a limited range substantially independently of the external case 102. This soft disk drive suspension 1 15 may help isolate these two components of the external disk drive 100, thus helping to mitigate external shocks to the disk drive 104 as well as to prevent the external case 102 from vibrating based on internal vibrations induced by the rotation of disks or the movement of actuators.

Figures 2 and 3 show perspective and top views, respectively, of a printed circuit board (PCB) 1 16, the first and second light pipes 106, 108 and a light source 1 18. As illustrated therein, the first light pipe 106 may be mechanically coupled near a "front" of the PCB 1 16, substantially covering the light source 1 18. Of course, in different embodiments, the first light pipe 106 may be coupled to the PCB 1 16 at any of a variety of locations, just as the light source 1 18 may be positioned at any of a variety of locations. The PCB 1 16 may also hold a variety of other disk drive circuitry, including a disk drive controller for controlling read and write operations and a servo control system for generating servo control signals.

Figures 4 and 5 show perspective and side magnified views, respectively, of the first light pipe 106, the second light pipe 108, and the light source 1 18. As is shown in Figures 4 and 5, the first light pipe 106 may include a first optical quality surface 120 proximate to and facing the light source 1 18, and a second optical quality surface 122 proximate to and facing the second light pipe 108. These optical quality surfaces 120, 122 may be polished or otherwise prepared to efficiently receive and/or emit light and to minimize reflectance. In one embodiment, the first optical quality surface 120 comprises a rectangular surface having a larger surface area than that of the rectangular light source 1 18. In another embodiment, the first optical quality surface 120 may have any of a variety of geometrical shapes and may be larger or smaller than the light source 1 18. The second optical quality surface 122 may also comprise a rectangular surface, although this surface 122 may also have any of a variety of shapes and sizes.

The first optical quality surface 120 may be separated from the light source 1 18 by less than 1 mm, in order to improve light transmission between the light source 1 18 and the first light pipe 106. In some embodiments, the first optical quality surface 120 may be separated from the light source 118 by less than 0.5 mm. In one embodiment, only air may separate the first optical quality surface 120 from the light source 118. However, in other embodiments, other materials may be inserted between these components in order to improve light transmission between the light source 1 18 and the first light pipe 106. The second light pipe 108 may include a third optical quality surface 124 proximate to and facing the second optical quality surface 122 (as best shown in Figure 5). The third optical quality surface 124 may also be polished or otherwise prepared to efficiently receive light and minimize reflectance. In one embodiment, the third optical quality surface 124 may have a surface area greater than a surface area of the second optical quality surface 122. Thus, if the first light pipe 106 moves relative to the second light pipe 108, the third optical quality surface 124 may be dimensioned to continually receive light emitted through the second optical quality surface 122 during such motion. In other embodiments, the third optical quality surface 124 may have any of a variety of geometrical shapes and may be larger or smaller than the second optical quality surface 122.

As best shown in Figure 5, the first light pipe 106 is separated from the second light pipe 108 by a distance D. In particular, the second optical quality surface 122 and the third optical quality surface 124 are separated by the distance D. In one embodiment, the distance D is less than 1 mm. In another embodiment, the distance D is between 0.25 and 0.75 mm. If the distance D is too great, light transmission between the first and second light pipes 106, 108 may be adversely impacted, but, if the distance D is too small, the first light pipe 106 and the second light pipe 108 have less room to move relative to one another.

In one embodiment, the separation between the first light pipe 106 and the second light pipe 108 enables the first light pipe 106 to move relative to the second light pipe 108. In particular, in one embodiment, the first light pipe 106 may be configured to move within a range of motion substantially independently of the second light pipe 108. As discussed above, in one embodiment, a disk drive suspension 1 15 may be positioned between the disk drive 104 and the external case 102, such that these components may move relative to one another within some range defined by the range of motion of the disk drive suspension 1 15. Thus, these small relative movements may be accommodated, in one embodiment, while maintaining a light path between the light source 1 18 and the status lens 1 10.

Figure 6 illustrates a simulated light path 126 for light emitted by the light source 1 18 that travels through the first light pipe 106 and the second light pipe 108. As illustrated, the light path 126 for this light is defined through the first optical quality surface 120, the second optical quality surface 122 and the third optical quality surface 124. In one embodiment, the light path 126 may be logically divided into a first light path 126a and a second light path 126b defined through the first light pipe 106 and the second light pipe 108, respectively. These light paths 126a, b may together form part of a complete light path 126 for light emitted by the light source 1 18 to the status lens 1 10. The first light path 126a is defined by the first light pipe 106. As illustrated, the first light path 126a may include one 90 degree bend 128a. This 90 degree bend 128a may be defined by an external surface of the first light pipe 106, as illustrated, or may be defined by one or more internal features of the first light pipe 106. The second light path 126b is defined by the second light pipe 108. As illustrated, the second light path 126b may include three 90 degree bends 128b, c, d before the status lens 1 10. The three 90 degree bends 128b, c, d may be defined by external surfaces of the second light pipe 108, as illustrated, or may be defined by one or more internal features of the second light pipe 108. Of course, in other embodiments, the light path 126 may include any number of turns / bends along its length between the light source 1 18 and the status lens 1 10. These turns / bends may also be divided between the first light pipe 106 and the second light pipe 108 in a variety of ways. Figures 7A-7D illustrate the first light pipe 106 from a variety of angles. In one embodiment, the first light pipe 106 is configured and dimensioned to mechanically couple to the disk drive 104. As illustrated, the first light pipe 106 may include at least one pair of outwardly facing prongs 130a configured to interface with a hole formed through the PCB 1 16. In one embodiment, the first light pipe 106 includes two pairs of prongs 130a, 130b to provide a secure snap fit coupling between the first light pipe 106 and the PCB 1 16.

Figures 8A-8E illustrate the second light pipe 108 from a variety of angles. The second light pipe 108 may be shaped and configured in a variety of ways, and the external surfaces of the second light pipe 108 may be oriented to define the second light path 126b from the third optical quality surface 124 to the status lens 1 10.

Figure 9 illustrates a flow chart for a method 900 of manufacturing an external disk drive, according to one illustrated embodiment. This method 900 will be discussed in the context of the external disk drive 100 of Figures 1 -8. However, the acts disclosed herein may be executed to produce a variety of different external disk drives, in accordance with the described method.

As described herein, at least some of the acts comprising the method 900 may be orchestrated by a processor according to an automatic disk drive manufacturing algorithm, based at least in part on computer-readable instructions stored in computer-readable memory and executable by the processor. A manual implementation of one or more acts of the method 900 may also be employed, in other embodiments.

At act 902, an external case 102 and a disk drive 104 are provided, the disk drive 104 including a light source 1 18 configured to emit light indicative of a disk drive status. In one embodiment, the external case 102 may be provided as a plurality of modular pieces that may be joined at a later stage to surround the disk drive 104. The disk drive 104, too, may be provided before it has been completely assembled. At act 904, a first light pipe 106 and a second light pipe 108 are provided. As described above, the first light pipe 106 and the second light pipe 108 may comprise polycarbonate or acrylic pieces. In one embodiment, the first light pipe 106 and the second light pipe 108 may be produced from molds and then provided at an external disk drive assembly line.

At act 906, the first light pipe 106 is coupled to the disk drive 104 such that the first light pipe 106 is positioned to directly receive and guide light emitted by the light source 1 18. The first light pipe 106 may be coupled to the disk drive 104 in a variety of ways. In one embodiment, as illustrated, a snap fit coupling may be formed between the two components. In other embodiments, other coupling structures may be used.

A robotic arm may be used to couple the first light pipe 106 to the disk drive 104. For example, the first light pipe 106 may be coupled to a printed circuit board 1 16 using a robotic arm, and the PCB 1 16 may then be coupled to the rest of the disk drive 104.

At act 908, the second light pipe 108 is coupled to the external case 102. The second light pipe 108 may be coupled to the external case 102 in a variety of ways. In one embodiment, an elongate feature of the second light pipe 108 defining the status lens 1 10 may be inserted through a hole 114 in the external case 102, and these components may then be ultrasonically welded. In other embodiments, other coupling structures may be used. These coupling structures may connect the second light pipe 108 to the external case 102 at a number of different locations.

At act 910, the disk drive 104 is positioned within the external case 102 such that the second light pipe 108 is separated from the first light pipe 106 and positioned to receive and guide light from the first light pipe 106 to a status lens 1 10. The disk drive 104 and the external case 102 may be positioned relative to one another in a variety of ways. In one embodiment, the disk drive suspension 1 15 may first be coupled to the corners of the disk drive 104. The external case 102 may then be positioned around and mechanically coupled to the disk drive suspension 115, such that the disk drive 104 is positioned within the external case 102. In other embodiments, the external case 102 may remain fixed, while the disk drive 104 is placed into an interior of the external case 102. The foregoing detailed description has set forth various embodiments of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one embodiment, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, the embodiments disclosed herein, in whole or in part, can be equivalent^ implemented in standard integrated circuits, as one or more programs executed by one or more processors, as one or more programs executed by one or more controllers {e.g., microcontrollers), as firmware, or as virtually any combination thereof.