U.S. patent application number 11/205414 was filed with the patent office on 2006-03-02 for cushion for packing disks such as semiconductor wafers.
Invention is credited to Song Ping Chen, Clifton C. Haggard, Mao Shi Khoo, Ru Zheng Liu, James R. Thomas.
Application Number | 20060042998 11/205414 |
Document ID | / |
Family ID | 36113050 |
Filed Date | 2006-03-02 |
United States Patent
Application |
20060042998 |
Kind Code |
A1 |
Haggard; Clifton C. ; et
al. |
March 2, 2006 |
Cushion for packing disks such as semiconductor wafers
Abstract
A cushion device (40) for packing disks (22) such as
semiconductor wafers has a base (42) that is selectively secured
within a container (20). The cushion (40) includes a plurality of
cushion members (60) each having two ends supported by the base
(42). In a disclosed example, the cushion members (60) have a
stepped configuration between the two ends. Angles between adjacent
generally linear portions of the stepped configuration change as
the cushion members flex responsive to engaging a semiconductor
wafer within the container. A disclosed example includes a
contacting portion (90) near a vertex (92) between two adjacent
linear portions of a cushion member (60). One example has
contacting portions (90) of aligned cushion members spaced at an
angle between about 65.degree. and about 180.degree..
Inventors: |
Haggard; Clifton C.;
(Austin, TX) ; Thomas; James R.; (Austin, TX)
; Chen; Song Ping; (ShenZhen, CN) ; Liu; Ru
Zheng; (ShenZhen, CN) ; Khoo; Mao Shi;
(ShenZhen, CN) |
Correspondence
Address: |
CARLSON, GASKEY & OLDS, P.C.
400 WEST MAPLE ROAD
SUITE 350
BIRMINGHAM
MI
48009
US
|
Family ID: |
36113050 |
Appl. No.: |
11/205414 |
Filed: |
August 17, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60603873 |
Aug 24, 2004 |
|
|
|
Current U.S.
Class: |
206/711 ;
206/591 |
Current CPC
Class: |
H01L 21/67369
20130101 |
Class at
Publication: |
206/711 ;
206/591 |
International
Class: |
B65D 85/30 20060101
B65D085/30; B65D 81/02 20060101 B65D081/02 |
Claims
1. A device for packing at least one disk, comprising; a base; and
a plurality of cushion members having a first end supported by the
base and a second end supported by the base, each cushion member
having a plurality of generally linear segments between the first
and second ends, adjacent ones of the generally linear segments are
transverse to each other, each cushion member having at least one
contacting portion for contacting a disk near at least one vertex
between two of the generally linear segments.
2. The device of claim 1, comprising a first plurality of the
cushion members having first ends supported near one lateral edge
of the base and second ends supported near a central portion of the
base and a second plurality of the cushion members having first
ends supported near an opposite lateral edge of the base and second
ends supported near the central portion of the base.
3. The device of claim 2, wherein the second ends of the first
plurality of cushion members is spaced from the first ends of the
second plurality of cushion members.
4. The device of claim 2, wherein the base includes openings
between the first and second ends of each of the plurality of
cushion members.
5. The device of claim 4, wherein the base includes spaced apart
support portions near the central portion of the base, each of the
spaced apart support portions supporting the second ends of a
corresponding one of the plurality of cushion members.
6. The device of claim 1, wherein each cushion member has a
plurality of the contacting portions.
7. The device of claim 1, wherein a first of the cushion members
and a second of the cushion members aligned with and parallel to
the first cushion member are positioned so that the contacting
portions of the first and second cushion members are spaced apart
such that an angle between respective reference lines from each of
the first and second cushion member contacting portions to a point
corresponding to a center of a disk if the disk were engaged by the
first and second cushion members is in a range from about
65.degree. to about 180.degree..
8. The device of claim 7, wherein the angle is in range from about
100.degree. to about 170.degree..
9. The device of claim 7, wherein the angle is in a range from
about 120.degree. to about 160.degree..
10. The device of claim 7, wherein the angle is about
150.degree..
11. The device of claim 1, wherein each generally linear segment of
each cushion member is generally perpendicular to an adjacent
linear segment of the corresponding cushion member.
12. The device of claim 11, wherein at least the linear segments on
each side of the vertex near the contacting portion of each cushion
member move relative to each other responsive to engagement between
the contacting portion and a disk.
13. The device of claim 1, comprising a container top and a
container bottom adapted to contain at least one disk and wherein
the base is received at least partially against a portion of the
top.
14. The device of claim 13, wherein the top includes a plurality of
locking members that secure the base in a desired position relative
to the top.
15. A device for packing at least one disk, comprising: a base; and
a plurality of cushion members depending from the base, each
cushion member having at least one contacting portion for
contacting a surface on a disk, the contacting portion on a first
cushion member and the contacting portion on a second cushion
member aligned with and parallel to the first cushion member are
spaced apart such that an angle between respective reference lines
from each of the first and second cushion member contacting
portions to a point corresponding to a center of a disk if the disk
were engaged by the first and second cushion members is in a range
from about 65.degree. to about 180.degree..
16. The device of claim 15, wherein the angle is in range from
about 100.degree. to about 170.degree..
17. The device of claim 15, wherein the angle is in a range from
about 120.degree. to about 160.degree..
18. The device of claim 15, wherein the angle is about
150.degree..
19. The device of claim 15, wherein each cushion member includes a
first end supported by the base and a second end supported by the
base, each cushion member having a plurality of generally linear
segments between the first and second ends with the at least one
contacting portion for contacting a disk near at least one vertex
between two of the generally linear segments.
20. The device of claim 19, wherein each generally linear segment
of each cushion member is generally perpendicular to an adjacent
linear segment of the corresponding cushion member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/603,873, which was filed on Aug. 24, 2004.
FIELD OF THE INVENTION
[0002] This invention generally relates to packing disks such as
semiconductor wafers. More particularly, this invention relates to
a cushion device for use in packing disks.
DESCRIPTION OF THE RELATED ART
[0003] Semiconductor wafers typically include an array of
integrated circuits on a disc of semiconductor material. The wafers
typically are manufactured in one location, packaged and shipped to
another location and then arranged in particular devices. The
wafers and the circuits on them must be protected during the
packaging and shipping stages of a normal production cycle.
[0004] A variety of packages have been developed for packing and
shipping semiconductor wafers. One known type of package receives a
stack of wafers between a top and bottom with a plurality of
separators and cushions within the container. Another type of
container includes a cassette that receives a series of wafers and
the cassette is received between a container top and bottom. Known
containers include some form of cushion to bias the wafers into a
proper position within the cassette. Examples are shown in U.S.
Pat. Nos. 4,966,284 and 5,228,568. The arrangement in the first of
these patents relies upon cantilevered arms that are formed as part
of the top of the container. One disadvantage of this arrangement
is that molding the container top is complicated by the presence of
the cantilevered arms. Another shortcoming of that arrangement is
that the cantilevered arms may not provide a reliable and desired
level of bias after several uses.
[0005] The separate cushion of the second patent mentioned above
has an advantage over the first example because it simplifies the
molding process for making the container top. On the other hand,
that arrangement still includes cantilevered cushion members that
suffer from the same shortcoming as those in the first patent
mentioned above.
[0006] There is a need for an improved arrangement for packing
semiconductor wafers or other sensitive disks in a container that
includes a cassette for receiving and supporting the wafers. This
invention provides an improved cushion that satisfies that
need.
SUMMARY OF THE INVENTION
[0007] An exemplary disclosed embodiment of a device for packing at
least one disk includes a base. A plurality of cushion members each
have a first end supported by the base and a second end supported
by the base. Each cushion member has a plurality of generally
linear segments between the first and second ends. Adjacent
generally linear segments are transverse to each other. Each
cushion member has at least one contacting portion for contacting a
disk. The contacting portions are located near at least one vertex
between two of the generally linear segments.
[0008] One example includes contacting portions on first and second
cushion members that are aligned with each other for contacting a
single disk. The contacting portions are spaced apart such that an
angle between respective reference lines from each of the first and
second cushion member contacting portions to a point corresponding
to a center of a disk if a disk were engaged by the first and
second cushion members is in a range from about 65.degree. to about
180.degree.. In a disclosed example, the angle is in a range from
about 120.degree. to about 160.degree.. In one example, the angle
is about 150.degree.. Spacing the contacting portions in this way
facilitates better handling during packing and better stability
during shipping, for example.
[0009] The various features and advantages of this invention will
become apparent to those skilled in the art from the following
detailed description of the currently preferred embodiments. The
drawings that accompany the detailed description can be briefly
described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 schematically illustrates a container designed
according one embodiment of this invention.
[0011] FIG. 2 shows an elevational view of an example cushion.
[0012] FIG. 3 is a cross-sectional illustration taken along the
lines 3-3 in FIG. 2.
[0013] FIG. 4 is an elevational view of another example
cushion.
[0014] FIG. 5 is a cross-sectional illustration taken along the
lines 5-5 in FIG. 4.
[0015] FIG. 6 shows selected features of one example container
portion.
[0016] FIG. 7 schematically illustrates a feature of an example
embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] An example container 20 is schematically shown in an
assembled condition in FIG. 1. The container 20 is configured to
safely package a plurality of wafers or disks 22. The container 20
includes a first portion 24 and a second portion 26, which are
secured together by a locking arrangement at 28. In one example,
the locking arrangement 28 includes hooks on one of the first or
second portions 24 or 26 and an opening on the other such that the
hooks are partially received in the opening to secure the portions
together.
[0018] In the illustrated example, the first portion 24 receives a
cassette 30. The wafers are received into the cassette 30 in a
known manner. The cassette 30 is configured to support the wafers
22 in a manner that keeps them spaced from each other and in a
generally stable position within the container 20.
[0019] Part of the wafer outer surfaces engage grooves on the
cassette 30 and another part of the outer surfaces engage a cushion
40. In the illustrated example, the cushion 40 is snap fit into a
secured position relative to the second portion 26. The cushion 40
biases the wafers 22 into a stable position within the cassette 30
and keeps the wafers 22 from shifting about within the container 20
during shipping and handling.
[0020] The example cushion 40 shown in FIGS. 2 and 3 includes a
base that is at least partially received within the second portion
26 of the container 20. The base 42 in this example includes a
first support portion 44 along one lateral edge and a second
support portion 46 along a second, opposite lateral edge.
Additional support portions 48 and 50 are near a center of the base
42. The illustrated example includes an open space 52 between the
support portions 48 and 50.
[0021] The example base 42 also has cross bars 54 and 56 that are
generally perpendicular to the support portions 44-50. The cross
bars 54 and 56 and the support portions 44-50 are rigid and the
base 42 is self-supporting in one example. The base 42 is adapted
to be snap fit into the second portion 26 of the container 20 so
that cushion members 60 extend toward the wafers in the cassette
30.
[0022] The example cushion 40 includes a plurality of cushion
members 60 that have a generally stepped configuration when viewed
from the perspective of FIG. 3. In this example, a plurality of
generally linear portions 62, 64, 66, and 68 are transversely
oriented relative to an adjacent one of the generally linear
portions. In this example, the generally linear portions are
generally perpendicular relative to an adjacent linear portion.
[0023] One end 70 of each cushion member is supported by one of the
lateral support portions 44 or 46. In the illustrated example, the
end 70 is supported near an end of an arm 72 that extends from the
corresponding support portion 44, 46 such that the end 70 of the
cushion members is spaced a selected distance from the base 42. In
this example, each arm 72 is rigid in a longitudinal direction of
the arm (i.e., in a direction extending between the end 70 of the
cushion member and the corresponding support portion 44, 46). In
one example, the arms 72 comprise continuous sides of the cushion
that are not separated at the position of each cushion member 60.
In another example, each cushion member 60 has a dedicated arm 72
that is separate from the other arms 72. In still another example,
the arms 72 are partially integrated and partially separated.
[0024] An opposite end 74 of each cushion member 60 is supported by
one of the example support portions 48, 50 near a center of the
base 42. In this example, the second end 74 is supported
immediately adjacent the corresponding support portion 48, 50
without any intervening arm.
[0025] Having fixed ends 70 and 74 supported by the base 42
provides a more stable arrangement and a more consistently reliable
bias and cushion effect compared to previous designs that rely on
cantilevered fingers. The stepped configuration of the cushion
members 60 and the material selected to form the cushion 40 provide
resiliency between the fixed, supported ends 70 and 74 that allows
wafers or disks to be received between the cushion 40 and the
cassette 30 without any risk of damage to the wafers or disks under
expected handling procedures. One example material is
polypropylene.
[0026] In the illustrated example, each cushion member 60 has a
corresponding cushion member on an opposite side of a center of the
cushion 40 such that two cushion members 60 are aligned with each
other to engage each wafer received between the cushion 40 and the
cassette 30. Each cushion member in one example has a grooved
wafer-receiving surface that tends to center a corresponding
portion of a wafer edge along the cushion member.
[0027] The illustration of FIG. 3 shows the cushion members 60 in a
first configuration where the stepped configuration has a first
angle between adjacent ones of the generally linear portions 62-68.
When the cushion 40 engages at least one wafer within the container
20, at least some of the linear portions 62-68 move responsive to
contact with the wafer such that the relative angle between them
changes. In one example, at least the centrally located linear
portions move as the cushion member 60 flexes and the angle between
the adjacent moving pieces becomes larger.
[0028] FIGS. 4 and 5 show another example cushion 40', which may be
useful for packaging wafers of a different size or different type
than wafers for which the example cushion 40 of FIGS. 2 and 3 is
suitable. In this example, each cushion member 60' has fewer linear
portions 80, 82, 84 and 86 compared to the example of FIGS. 2 and
3. In this example the second ends 74' of the cushion members 60'
are secured to a single support portion 48 near a center of the
base 42. Otherwise the cushion 60' performs like the cushion 60 of
the previously described example.
[0029] Referring to FIG. 7, a feature of a disclosed example is
schematically illustrated, which provides better interaction
between the cushion members 60 and the disk 62 especially during
assembly of the container 20. Conventional wisdom has been to
arrange a cushion member near a top of a container such that the
cushion member contacts a disk near a top edge of the disk within
the container. Considering the positions on the face of an analog
clock, most cushion designs make contact with the disk between 11
o'clock and 1 o'clock . One example embodiment of this invention
includes spacing apart contact locations between the cushion
members and a disk to provide a more stable arrangement.
[0030] Referring to FIGS. 1 and 5, each cushion member 60 includes
at least one contacting portion 90 near a vertex 92 between two
adjacent generally linear segments of the cushion member. The
example in FIG. 1 has two contacting portions 90 for each cushion
member 60. The example of FIG. 5 has one contacting portion 90 for
each cushion member 60'. The contacting portions 90 in the
illustrated examples are located near a vertex 92 between generally
perpendicularly aligned, adjacent linear portions of the cushion
member.
[0031] As can be appreciated from FIG. 7, one example includes
positioning the contacting portions 90 such that they are spaced
apart so that when they contact a disk 22, an angle between
respective reference lines 94 and 96 is within a selected range
that is greater than the conventional spacing. In FIG. 7, the
example disk 22 has a center point 98. The reference lines 94 and
96 are taken between the contacting portions 90 and the center
point 98. An angle .alpha. between the reference lines 94 and 96 in
one example is within the illustrated range shown at 99 (e.g., the
shaded region in the illustration). In one example, the range
extends from about 65.degree. to about 180.degree.. One example
includes positioning the contacting portions to be within a range
from about 90.degree. to about 170.degree.. A more particular
example includes a range for the angle .alpha. between about
120.degree. and about 160.degree.. In one particular example, the
angle .alpha. is set to about 150.degree.. Using the face of a
clock for discussion purposes, one example includes positioning the
contacting portions 90 so that they make contact with an edge of a
corresponding disk 22 between about 9 o'clock and about 10:30 on
one side and between about 1:30 and 3 o'clock on the other
side.
[0032] Keeping the angle .alpha. greater than 65.degree. and less
than 180.degree. provides better handling procedures. During
assembly of a container 20, as the top portion 26 is placed in
position on the bottom 24, with conventional arrangements, there is
a tendency for more than one disk to be engaged by a set of
corresponding cantilevered fingers, for example. This is due, in
part, because of the close proximity of the positions where such
fingers contact the disks (i.e., within a range less than
60.degree. apart). By spacing apart the contacting portions 90 a
greater distance, the illustrated example reduces a tendency for
more than one disk to be engaged by a corresponding set of cushion
members 60 as the container is assembled into a closed
condition.
[0033] Keeping the contacting portions 90 further down the sides of
a disk within the range illustrated at 99 in FIG. 7 also provides
enhanced stability for keeping the disks in a more fixed position
within a container 20 during shipping and handling, for example.
The wider spring cooperates with other features of the container
assembly to limit lateral movement of the disks 22.
[0034] The second portion 26 of the container 20 in the example of
FIG. 6 includes a locking feature 100 on an inside surface 102 for
securing a selected cushion 40 in place within the container 20. In
one example the locking feature comprises a plurality of tabs that
are arranged to allow the base 42 to snap into place on the second
portion 26. The same locking feature allows the cushion 40 to be
selectively removed from the rest of the container. One advantage
to this example arrangement is that it allows the cushion 40 to be
replaced or recycled without requiring the entire container 20 to
be replaced or recycled. If one portion of the container 40 becomes
damaged, for example, that portion can be replaced without the
material costs of replacing the entire container or more than one
portion of the container.
[0035] The preceding description is exemplary rather than limiting
in nature. Variations and modifications to the disclosed examples
may become apparent to those skilled in the art that do not
necessarily depart from the essence of this invention. The scope of
legal protection given to this invention can only be determined by
studying the following claims.
* * * * *