U.S. patent application number 10/284074 was filed with the patent office on 2003-06-05 for method and apparatus for flattening cover tape.
This patent application is currently assigned to Robotic Vision Systems, Inc.. Invention is credited to Behnke, Merlin E..
Application Number | 20030101692 10/284074 |
Document ID | / |
Family ID | 23312288 |
Filed Date | 2003-06-05 |
United States Patent
Application |
20030101692 |
Kind Code |
A1 |
Behnke, Merlin E. |
June 5, 2003 |
Method and apparatus for flattening cover tape
Abstract
A method and apparatus for flattening cover tape prior to the
cover tape being sealed to a carrier tape. The apparatus includes a
cover tape flattener with a leading edge angled in the direction of
the moving carrier tape and cover tape. The method and apparatus
provide for smoothing the cover tape and sealing the cover tape to
the carrier tape.
Inventors: |
Behnke, Merlin E.; (Grafton,
WI) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH, LLP
100 E WISCONSIN AVENUE
MILWAUKEE
WI
53202
US
|
Assignee: |
Robotic Vision Systems,
Inc.
Canton
MA
|
Family ID: |
23312288 |
Appl. No.: |
10/284074 |
Filed: |
October 30, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60335560 |
Oct 31, 2001 |
|
|
|
Current U.S.
Class: |
53/471 ; 53/282;
53/329.4; 53/485 |
Current CPC
Class: |
B65B 11/50 20130101;
B65B 15/04 20130101; B65B 7/164 20130101 |
Class at
Publication: |
53/471 ; 53/282;
53/329.4; 53/485 |
International
Class: |
B65B 007/28 |
Claims
What is claimed is:
1. A part packaging apparatus for packaging parts in a carrier tape
having serially spaced-apart compartments and at least one flange
extending alongside the compartments, and for applying a cover tape
over the carrier tape, the carrier tape and cover tape traveling in
a downstream direction, the apparatus comprising: a part placement
head adapted to position parts in the carrier tape compartments; a
cover tape applicator for laying the cover tape over the carrier
tape; a flattening apparatus having a leading edge that contacts
the cover tape to smooth the cover tape; and a sealing apparatus
downstream of the flattening apparatus to seal the cover tape to
the carrier tape.
2. The apparatus of claim 1, wherein the flattening apparatus
includes a tube roller that defines the leading edge and rolls
across the cover tape to smooth the cover tape.
3. The apparatus of claim 1, wherein the flattening apparatus
includes at least two tube rollers that each define a leading edge
and that together define a peak that points in an upstream
direction.
4. The apparatus of claim 3, wherein the leading edges are swept
back from the peak in the downstream direction such that wrinkles
in the cover tape are smoothed to the sides as the cover tape moves
downstream.
5. The apparatus of claim 3, wherein the peak is centered with
respect to the side edges of the cover tape.
6. The apparatus of claim 3, wherein the flattening apparatus
includes a wire that extends longitudinally through the two tube
rollers to define an axis of rotation for the rollers, and wherein
the flattening apparatus further includes two mounting clamps
securing the ends of the wire to the packaging apparatus, wherein
the wire biases the roller tubes into contact with the cover
tape.
7. The apparatus of claim 1, wherein the leading edge extends to
the outer edges of the carrier tape.
8. The apparatus of claim 1, wherein the flattening apparatus
includes a plate that defines the leading edge and that glides
across the cover tape to smooth the cover tape.
9. The apparatus of claim 8, wherein the plate includes two edges
swept back from the peak in the downstream direction and extending
to the outer edges of the carrier tape.
10. The apparatus of claim 9, wherein a wire extends through the
plate such that the plate pivots about the wire and wherein the
flattening apparatus further includes two mounting clamps securing
the ends of the wire to the packaging apparatus, wherein the wire
biases the plate into contact with the cover tape.
11. The apparatus of claim 8, wherein the plate includes a cavity
on the bottom of the plate to reduce the surface area of the plate
that is in contact with the cover tape.
12. The apparatus of claim 1, wherein the cover tape is
transparent, and the apparatus further comprising an inspection
module to inspect the part in the compartment through the cover
tape.
13. A method of smoothing cover tape and sealing parts in a carrier
tape having serially spaced-apart compartments and at least one
flange extending alongside the compartments, the method comprising:
positioning parts in the carrier tape compartments; applying the
cover tape over the carrier tape; applying pressure on the cover
tape with a flattening apparatus having a leading edge as the cover
tape travels in a downstream direction; smoothing the cover tape as
it travels under the leading edge of the flattening apparatus; and
sealing the cover tape to the carrier tape.
14. The method of claim 13, wherein sealing the cover tape to the
carrier tape includes applying heat to the carrier tape to activate
adhesive on the cover tape.
15. The method of claim 13, wherein sealing the cover tape to the
carrier tape includes sealing the cover tape to the carrier tape
flange.
16. The method of claim 13, wherein smoothing the cover tape
includes removing wrinkles from the cover tape.
17. The method of claim 13, wherein smoothing the cover tape
includes removing wrinkles from the middle of the cover tape to the
outer edges of the cover tape.
18. The method of claim 13, wherein the flattening apparatus
includes a tube roller, and wherein smoothing the cover tape
includes rolling the tube roller across the cover tape to smooth
the cover tape.
19. The method of claim 13, wherein the flattening apparatus
includes a plate, and wherein smoothing the cover tape includes
gliding the plate across the cover tape to smooth the cover
tape.
20. The method of claim 13, wherein the cover tape is transparent,
and further comprising inspecting the part in its compartment
through the cover tape with an inspection module after the cover
tape is sealed to the carrier tape.
21. A part packaging apparatus for packaging parts in a carrier
tape having serially spaced-apart compartments and at least one
flange extending alongside the compartments, and for applying a
cover tape over the carrier tape, the carrier tape and cover tape
traveling in a downstream direction, the apparatus comprising: a
part placement head to position parts in the compartments; an
inspection module to inspect the part in the carrier tape
compartment; a flattening apparatus including a plate that glides
across the cover tape, the plate having a leading edge that
contacts the cover tape to smooth the cover tape, the leading edge
angled in the downstream direction and extending to the outer edges
of the carrier tape, a wire that extends through the plate such
that the plate pivots about the wire, and at least one mounting
clamp securing the end of the wire to the packaging apparatus,
wherein the wire biases the plate into contact with the cover tape;
a sealing apparatus to seal the cover tape to the carrier tape; and
a seal inspection module to inspect the part in the compartment
through the cover tape.
22. The apparatus of claim 21, wherein the plate includes two
leading edges that define a peak that points in an upstream
direction.
23. The apparatus of claim 22, wherein the leading edges are swept
back from the peak in the downstream direction such that wrinkles
in the cover tape are smoothed to the sides as the cover tape moves
downstream.
24. The apparatus of claim 22, wherein the peak is centered with
respect to the side edges of the cover tape.
25. The apparatus of claim 21, wherein the plate includes a cavity
on the bottom of the plate to reduce the surface area of the plate
that is in contact with the cover tape.
26. A part packaging apparatus for packaging parts in a carrier
tape having serially spaced-apart compartments and at least one
flange extending alongside the compartments, and for applying a
cover tape over the carrier tape, the carrier tape and cover tape
traveling in a downstream direction, the apparatus comprising: a
part placement head to position parts in the compartments; an
inspection module to inspect the part in the carrier tape
compartment; a flattening apparatus including a tube roller that
rolls across the cover tape to smooth the cover tape, the tube
roller having a leading edge that contacts the cover tape to smooth
the cover tape, the leading edge angled in the downstream direction
and extending to the outer edges of the carrier tape, a wire that
extends longitudinally through the tube roller to define an axis of
rotation for the roller, and at least one mounting clamp securing
the end of the wire to the packaging apparatus, wherein the wire
biases the tube roller into contact with the cover tape; a sealing
apparatus to seal the cover tape to the carrier tape; and a seal
inspection module to inspect the part in the compartment through
the cover tape.
27. The apparatus of claim 26, wherein the flattening apparatus
includes at least two tube rollers that each define a leading edge
and that together define a peak that points in an upstream
direction.
28. The apparatus of claim 26, wherein the leading edges are swept
back from the peak in the downstream direction such that wrinkles
in the cover tape are smoothed to the sides as the cover tape moves
downstream.
29. The apparatus of claim 26, wherein the peak is centered with
respect to the side edges of the cover tape.
Description
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/335,560, filed Oct. 31, 2001.
BACKGROUND
[0002] The invention relates to taper machines in which electronic
parts are positioned within the compartments of a carrier tape, and
in which a cover tape is laid over the carrier tape and sealed
thereto to trap the parts within the compartments. More
specifically, the invention relates to a method and apparatus for
flattening the cover tape prior to the cover tape being sealed to
the carrier tape.
SUMMARY
[0003] The present invention provides a flattening mechanism for
flattening wrinkles out of cover tape prior to the cover tape being
bonded to carrier tape. The flattening mechanism is biased against
the cover tape and includes a leading edge that is angled with
respect to the direction of travel of the cover tape. The leading
edge may be defined by rollers or a plate. As the cover tape moves
under the flattening mechanism, the wrinkles are flattened out to
edge of the carrier tape sides. The cover tape is therefore
substantially flat or planar as it is bonded to the carrier
tape.
[0004] Other features and advantages of the invention will become
apparent to those skilled in the art upon review of the following
detailed description, claims, and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a side elevation view of a taper machine embodying
the invention.
[0006] FIG. 2 is a top plan view of the taper machine.
[0007] FIG. 3 is a perspective view of a portion of carrier
tape.
[0008] FIG. 4 is a perspective view of the cover tape flattening
assembly.
[0009] FIG. 5 is a cross-section view taken along line 5-5 in FIG.
2.
[0010] FIG. 6 is a top view of the flattening mechanism in
operation.
[0011] FIG. 7 is a cross-section view taken along line 7-7 in FIG.
2.
[0012] FIG. 8 is a top plan view of an alternative flattening
mechanism in operation.
[0013] FIG. 9 is a bottom perspective view of the alternative
flattening mechanism.
[0014] Before one embodiment of the invention is explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangements
of the components set forth in the following description or
illustrated in the drawings. The invention is capable of other
embodiments and of being practiced or being carried out in various
ways. Also, it is understood that the phraseology and terminology
used herein is for the purpose of description and should not be
regarded as limiting. The use of "including" and "comprising" and
variations thereof herein is meant to encompass the items listed
thereafter and equivalents thereof as well as additional items. The
use of "consisting of" and variations thereof herein is meant to
encompass only the items listed thereafter. The use of letters to
identify elements of a method or process is simply for
identification and is not meant to indicate that the elements
should be performed in a particular order.
DETAILED DESCRIPTION
[0015] FIGS. 1 and 2 illustrate an inspection, handling, and
packaging apparatus 20 that includes a support stand 24, an infeed
carrier tape drive wheel 26, a pick-and-place head or transport 28,
a carrier tape infeed reel 32 dispensing carrier tape 34, a
camera-over-tape or "COT" inspection module 36, a cover tape reel
40 dispensing cover tape 41, a cover tape flattening, smoothing, or
combing mechanism 42, a sealing shoe 44, a resilient drive roller
48, a backup wheel 50, a camera-after-sealing inspection module or
"CASI" module 52, and an output reel packaging module 56. The
support stand 24 supports a plurality of part input trays 60 that
contain parts 64 to be inspected and packaged. The transport 28
picks the parts 64 off the input trays 60, and transfers the parts
64 to the carrier tape 34. The transport 28 is preferably a
pick-and-place type transport utilizing a vacuum head.
[0016] The carrier tape 34 is best illustrated in FIG. 3, and
includes a pair of flanges 72 running along its length, and
compartments 76 formed between the flanges 72. One or both of the
flanges 72 may include sprocket holes 80 to facilitate advancing
the carrier tape 34 through the apparatus 20 and/or other
machinery. For example, the infeed carrier tape drive wheel 26 may
be a pinwheel having sprocket pins that engage the sprocket holes
80 of the carrier tape 34. The drive wheel 26 may be driven under
power by a motor (not illustrated) to pull the carrier tape 34 off
the infeed reel 32. Alternatively, the drive wheel 26 may have a
smooth or flat surface and/or be passive or not driven by a
motor.
[0017] The resilient drive roller 48 rotates under the power of a
motor (not illustrated) to pull the carrier tape 34 through the
apparatus 20 in a downstream direction 82 (an upstream direction
being opposite the downstream direction 82). The flanges 72 of the
carrier tape 34 are pinched between the drive roller 48 and the
backup wheel 50 to facilitate the advancement of the carrier tape
34 under the influence of the rotating drive roller 48.
Alternatively, the drive roller 48 may include pins that engage the
sprocket holes 80 in the tape flanges 72 to facilitate advancing
the carrier tape 34 through the apparatus 20. The carrier tape 34
is supported at its flanges 72 by guide rails 84 (FIGS. 1, 5, and
7) that extend substantially the entire length of the apparatus
20.
[0018] Referring again to FIGS. 1 and 2, the transport 28 places a
single part 64 into each compartment 76 of the carrier tape 34. The
COT inspection module 36 is downstream of the transport 28, and
includes a camera, which inspects the parts 64 in the carrier tape
compartments 76 as the carrier tape 34 is advanced through the
apparatus 20.
[0019] The cover tape 41 is laid on top of the carrier tape 34
downstream of the COT inspection module 36, and is pulled through
the apparatus 20 along with the carrier tape 34. The cover tape 41
is guided from the cover tape reel 40 to the carrier tape 34 by a
plurality of tensioning rollers 92. The cover tape 41 extends
between the flanges 72 and completely covers the compartments 76.
The adhesive, which is on the cover tape 41 surface, faces the
carrier tape 34. Heat activated cover tape has adhesive across the
complete cover tape surface. Pressure sensitive activated cover
tape has only two strips 94 of adhesive (FIG. 4) that are located
over the flanges 72 of the carrier tape 34. The adhesive is used to
seal the cover tape 41 to the flanges 72 of the carrier tape
34.
[0020] Referring to FIGS. 1, 2, and 4-6, the flattening mechanism
42 is downstream 82 of the last tension roller 92 such that both
the cover tape 41 and carrier tape 34 pass under the flattening
mechanism 42. The flattening mechanism 42 includes a length of
spring wire 96, a pair of roller tubes 100, and a pair of mounting
clamps 104. To assemble the flattening mechanism 42, the spring
wire 96 is extended longitudinally through the roller tubes 100,
and the spring wire 96 is then bent into the shape illustrated. The
mounting clamps 104 secure the ends of the spring wire 96 to a
support structure 106 alongside the guide rails 84. The resiliency
of the spring wire 96 biases the roller tubes 100 downwardly
against the cover tape 41.
[0021] The spring wire 96 is bent at its center to define a peak
that points in the upstream direction. The roller tubes 100 are
therefore angled or swept back from the center of the cover tape 41
in the downstream direction 82 to the outer edges of the carrier
tape 34. The roller tubes 100, which are preferably made of brass
or any other suitable material, freely rotate about the spring wire
96 as the carrier tape 34 and cover tape 41 pass under the
flattening mechanism 42. The bottoms of the roller tubes 100
contact the cover tape 41 and define the leading edge of the
flattening assembly 42.
[0022] Referring to FIG. 6, because the roller tubes 100 are angled
with respect to the longitudinal extent of the cover tape 41 and
carrier tape 34 and with respect to the downstream direction 82,
wrinkles in the cover tape 41 are flattened, smoothed, or combed to
the edges of the carrier tape prior to the cover tape 41 and
carrier tape 34 moving under the sealing shoe 44 (i.e., the cover
tape 41 is substantially free from wrinkles downstream 82 of the
rollers 100). The flattening mechanism 42 therefore helps to
maintain the cover tape 41 in a substantially planar condition
immediately prior to the cover tape 41 being bonded to the carrier
tape 34 by the sealing shoe 44.
[0023] Referring now to FIGS. 1 and 7, the sealing shoe 44 is
immediately downstream of, and should be as close as possible to,
the flattening mechanism 42. The sealing shoe 44 includes a sealing
mechanism 108 that is either a spool-shaped wheel or longitudinal
flat shoe. The sealing mechanism 108 has flanges or edges 109
aligned over the flanges 72 of the carrier tape 34, and in
alignment with the lines of adhesive 94 on the cover tape 41 if
pressure sensitive adhesive is used. A downward force is applied to
the sealing mechanism 108 to pinch the cover tape 41 and carrier
tape 34 together between the sealing flanges 109 and the guide
rails 84.
[0024] If heat is required to activate the adhesive, heating
elements 110 (FIG. 7) may be inserted into the guide rails 84 under
the sealing shoe 44 for that purpose. Thus, as the carrier tape 34
and cover tape 41 pass under the sealing shoe 44, the adhesive
forms a bond (as at 112 in FIG. 6) between the cover tape 41 and
the carrier tape 34 to secure the cover tape 41 over the
compartments 76 of the carrier tape 34 and thereby trap the parts
64 within the compartments 76.
[0025] Referring back to FIGS. 1 and 2, the CASI module 52 is
downstream 82 of the sealing shoe 44 and includes a camera that
looks down at the tape 34, 41 (substantially as seen in FIG. 6
downstream 82 of the rollers 100) and inspects the sealing bonding
process for possible sealing shoe position errors or inconsistent
sealing perimeters. By flattening the cover tape 41 prior to
sealing it to the carrier tape 34, the flattening mechanism 42
helps to reduce false rejections by the CASI module 52. Such false
rejections may be caused by the camera of the CASI module 52
mistaking wrinkles in the cover tape 41 as flaws.
[0026] The loaded carrier tape 34 is then wound onto the output
reel-packaging module 56. The apparatus 20 also includes a
processor (not illustrated) that receives information from the COT
and CASI modules 36, 52. The processor has memory that records
which of the parts 64 have been indicated by the inspection modules
36, 52 as having flaws. The flawed tape sealing process or bad
parts in tape are later reviewed and, within another operational
processes, the good parts 64 are taken from the carrier tape 34 for
their end use.
[0027] FIGS. 8 and 9 illustrate an alternative construction of the
flattening mechanism 42. Similar elements in these drawings are
given the same reference numerals introduced above. In this
construction, the spring wire 96 extends across the cover tape 41
and carrier tape 34 substantially perpendicular to the downstream
direction 82 and to the longitudinal extent of the tapes 41, 34,
and the rollers 100 are replaced with a flattening plate 114 having
angled edges. The wire 96 extends through the flattening plate 114,
and the flattening plate 114 is pivotal about the wire 96. A pair
of set collars 118 are mounted to the wire 96 on either side of the
flattening plate 114 to prevent the flattening plate 114 from
sliding along the wire 96, and to maintain the flattening plate 114
over the cover tape 41.
[0028] The flattening plate 114 is angled or swept back from the
center of the cover tape 41 in the downstream direction 82 to the
outer edges of the carrier tape 34, substantially as the rollers
100 in the above-described first construction are. A cavity 122 is
provided in the bottom of the flattening plate 114 to reduce the
surface area of the flattening plate 114 that is in contact with
the cover tape 41. This in turn reduces the frictional forces
applied to the cover tape 41 by the flattening plate 114 and
therefore reduces the pulling force required to move the cover and
carrier tapes 41, 34 through the apparatus 20. The flattening plate
114 operates substantially as described above with respect to the
first construction, except that the leading edge of the flattening
plate 114 slides (as opposed to rolling) over the cover tape 41 to
flatten out wrinkles in the surface of the cover tape 41.
* * * * *