U.S. patent application number 11/229490 was filed with the patent office on 2006-03-23 for universal packaging tray for disk drive assembly.
Invention is credited to Michael S. Adams, Ronald E. JR. Thomas.
Application Number | 20060060496 11/229490 |
Document ID | / |
Family ID | 36072774 |
Filed Date | 2006-03-23 |
United States Patent
Application |
20060060496 |
Kind Code |
A1 |
Adams; Michael S. ; et
al. |
March 23, 2006 |
Universal packaging tray for disk drive assembly
Abstract
A universal component carrier tray for use in assembly line
production of disk drives includes a framework structure that
defines a number of openings of variable size and geometry. Tray
portions having form fitting structure for receiving the unique and
varying configured componentry of disk drives are removably
seatable into the openings. The framework and tray portions are
preferably injection molded for facilitating extended life and
better constaint of the componentry. The trays have stacking
structure allowing a plurality of the trays to be stacked whereby
each tray stacked above a tray serves as a retainer or closure for
the tray below that may prevent the components from being dislodged
or misoriented from the holding structure during handling of the
stack and protect the components from particulate
contamination.
Inventors: |
Adams; Michael S.; (New
Prague, MN) ; Thomas; Ronald E. JR.; (Mount Baldy,
CA) |
Correspondence
Address: |
PATTERSON, THUENTE, SKAAR & CHRISTENSEN, P.A.
4800 IDS CENTER
80 SOUTH 8TH STREET
MINNEAPOLIS
MN
55402-2100
US
|
Family ID: |
36072774 |
Appl. No.: |
11/229490 |
Filed: |
September 16, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60611064 |
Sep 17, 2004 |
|
|
|
Current U.S.
Class: |
206/725 ;
206/512; 206/561; 206/565; G9B/25.003 |
Current CPC
Class: |
G11B 25/043
20130101 |
Class at
Publication: |
206/725 ;
206/561; 206/565; 206/512 |
International
Class: |
B65D 85/00 20060101
B65D085/00; B65D 1/34 20060101 B65D001/34; B65D 21/00 20060101
B65D021/00 |
Claims
1. A universal component carrier system for use in assembly line
production of disk drives in combination with a plurality of sets
of disk drive componentry, each set of componentry comprising parts
for the assembly of a portion of or all or a disk drive, the
component carrier system comprising: a plurality of like configured
component carrier trays in a vertically stacked arrangement, each
tray comprising: a horizontally extending framework structure that
defines a plurality of openings, said framework structure having an
upper face; a plurality of removable inserts, each of said inserts
having a base surface with upwardly extending structure for form
fitting individual ones of said parts; and wherein each tray of
said stacked arrangement that is seated on another tray with
componentry therein provides a cover said disk drive components
contained in said another tray.
2. The universal component carrier system of claim 1, wherein the
framework structure is configured as a lattice structure and
wherein at least two of said openings of each carrier tray is of
varying geometry.
3. The universal component carrier system of claim 2 wherein each
of said inserts are held in position by friction between said
perimeter of said insert and said lattice structure.
4. The universal component carrier system of claim 2 further
comprising: a clip integral to said insert, said clip having a free
end extending beyond said perimeter of said insert; a retention
finger cantilevered from said upper face of said lattice structure
and extending over one of said openings; wherein said insert is
mounted between said retention finger and said support structure;
and said free end of said clip engages said lattice structure.
5. The universal component carrier system of claim 2 wherein each
tray serves as a lid or closure for a tray below for preventing
said disk drive components from being dislodged from said
inserts.
6. A method of arranging componentry for assembly of disk drives
comprising the steps of: (a) providing a plurality of stackable
like-configured component trays, each tray comprising a framework
base having a plurality of openings for receiving insert tray
portions, (b) placing in said plurality of openings a plurality of
tray portions, each tray portion having form fitting structure for
receiving disk drive componentry, (c) placing sets of disk drive
componentry in each of said tray portions, (d) stacking the
plurality of stackable like-configured component trays in a stack
and moving same to an assembly area whereby the componentry may be
removed from each of the component trays in the stack.
7. The method of claim 6 further comprising the step of injection
molding the plurality of like configured component trays.
8. The method of claim 7 further comprising the step of injection
molding the plurality of tray portions.
9. A component tray system for assembly of hard disk drives
comprising a component tray having: a lattice structure having a
frame portion and at least one cross-member integral to said frame
portion that defines a plurality of openings, said lattice
structure having a lower surface that defines a registration plane;
a support structure that depends from said lattice structure, said
support structure extending laterally into said openings and having
an upper surface that is substantially flush with said registration
plane; a removable insert having a mounting surface, a leading edge
and a perimeter, said perimeter dimensioned to fit within one of
said openings, said insert contacting said support structure when
placed in said opening; a plurality of protrusions extending from
said mounting surface, said protrusions arranged and shaped to
secure a component.
10. The component tray system of claim 9 wherein at least one of
said cross-members includes a rib portion extending below said
lower surface of said cross-member.
11. The component tray system of claim 9 wherein said perimeter of
said insert slidably engages said lattice structure, thereby
frictionally retaining said insert within said lattice
structure.
12. The component tray system of claim 9 further comprising a
multiplicity of nubs that protrude laterally from said lattice
structure into said openings, such that said perimeter of said
insert slidably engages said nubs, thereby frictionally retaining
said insert within said lattice structure.
13. The component tray system of claim 9 wherein said component is
oriented to have an upper extremity, said protrusions being
dimensioned to position said upper extremity at a predetermined
distance from said registration plane.
14. The component tray system of claim 13 further comprising: a
retention finger depending from said lattice structure and
extending partially over at least one of said openings; a clip
having a proximate end portion depending from said insert and a
distal end portion opposite said proximate end portion; and wherein
said leading edge of said insert fits beneath said retention finger
and said distal end portion of said clip engages said lattice
structure.
15. The component tray system of claim 14 wherein said distal end
portion of said clip further comprises a barb, said barb engaging
said lower surface of said lattice structure.
16. The component tray system of claim 15 further comprising a
plurality of spacers extending upward from said lattice
structure.
17. The component tray system of claim 16 further comprising: an
upper component tray; a lower component tray; said upper component
tray being supported by said spacers of said lower component tray;
and said upper component tray contacting said component of said
lower component tray to retain said component of said lower
component tray on said protrusions of said insert of said lower
component tray.
18. The component tray system of claim 16 further comprising: an
upper component tray; a lower component tray; said upper component
tray being supported by said spacers of said lower component tray;
and said upper component tray contacting at least one of said
protrusions to retain said component of said lower component tray
on said protrusions of said insert of said lower component
tray.
19. The component tray system of claim 16 further comprising: a
lower component tray; an upper component tray having a skirt
projecting downward from said lattice structure of said upper
component tray; and wherein said upper component tray is placed
over said lower component tray to enclose said component of said
lower component tray.
20. The component tray system of claim 16 further comprising: a
lower component tray having a ridge extending upward from said
lattice structure of said lower component tray; an upper component
tray having a skirt projecting downward from said lattice structure
of said upper component tray; and wherein said skirt of said upper
component tray and said ridge of said lower component tray
cooperate to enclose said component of said lower component
tray.
21. The component tray system of claim 16 wherein said lattice
structure and said support structure is injection molded.
22. The component tray system of claim 16 wherein said plurality of
inserts are injection molded.
23. A component tray system for assembly of hard disk drives
including a component tray and a set of disk drive components for
assembly of a single disk drive, said tray comprising: a lattice
structure defining a plurality of tray portion receiving regions; a
plurality of removable tray portions sized to seat within said tray
portion receiving regions; form fitting structure on said removable
tray portions sized for constraining individual components of said
set of disk drive components for assembly of said single disk
drive.
24. The component tray system of claim 23 further comprising a
plurality of like configured trays arranged in a stack, each tray
having stacking structure to laterally constrain each tray with
respect to an adjacent stacked tray.
Description
RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional
Application Ser. No. 60/611,064, filed Sep. 17, 2004, which is
hereby fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to component trays. In
particular, the invention relates the component trays for use in an
assembly line production of hard disk drives.
BACKGROUND OF THE INVENTION
[0003] The assembly of hard disk drives for the computer industry
involves the conveyance of component parts through a manual
assembly line. The components are typically loaded into a pocket
tray carrier like the one shown in prior art FIG. 1. The pocket
tray may be used to arrange the components in a sequential manner
relative to the assembly process, as well as in a particular
orientation that allows the assembler to complete a task more
efficiently. Often, the pocket trays are loaded in advance and are
stored for a period of time before being transported through the
assembly process. As a practical matter, storage of the loaded
trays involves stacking and relocating them to a temporary storage
area.
[0004] During the assembly process, the loaded trays are placed on
a conveyor for transport through the various phases of assembly.
Assemblers must remove the components from the pocket tray by hand.
At the end of the assembly process, the empty trays are typically
collected and cleaned before being returned to start the process
anew.
[0005] The pocket tray of prior art FIG. 1 was fabricated using a
thermoforming process. The shape of the various pockets, as well as
the protrusions and recesses unique to each pocket, aid in the
preferred sequencing and the proper orientation of the components
for the assembly process.
[0006] There are certain inherent disadvantages to using the
thermoformed pocket tray for assembly line processing. The pocket
concept often makes it difficult to remove certain components from
the tray. Some of the smaller components that are housed in the
lower recesses of a given pocket are difficult to grasp with human
fingers. Also, in the process of stacking, relocating and
unstacking the pocket trays, the components do not always retain
the preferred orientation. These problems tend to slow the assembly
process, thereby reducing overall productivity.
[0007] The pocket tray carrier is also inherently difficult to
clean. The pocket geometry is prone to recirculation in the corner
regions during the wash down process. The recirculating solution
can collect in these areas and leave a residue that is undesirable
from the standpoint of contamination control.
[0008] Finally, the thermoformed tray has a life expectancy of only
a few months. The thin walls and cross members are subject to wear
and fracture after repeated washing, stacking and handling.
SUMMARY OF THE INVENTION
[0009] The various embodiments of the invention herein presented
feature an improved component tray system for the assembly of hard
disk drives. A plurality of stackable like-configured trays each
have a framework preferably configured as a framed lattice
structure of cross-members and periphery members defining a
plurality of openings with a plurality of tray portions removably
seated therein. Each tray portion having form-fitting structure for
constraining various componentry for assembly of disk drives.
[0010] In a preferred embodiment, the lower edges of the
cross-members and periphery members may be flush with respect to
each other so as to define a registration plane. Each of the
openings have at least one support that extends laterally from the
lower edges of cross-members such that the upper surfaces of the
supports are flush with the registration plane.
[0011] A plurality of inserts configured as individual tray
portions, preferably one tray portion for each opening in the
lattice structure, are dimensioned to seat within the openings,
thereby registering against the upper surfaces of the supports and
preferably frictionally engaging against the cross-members of the
respective opening.
[0012] The inserts each have a base, floor surface or mounting
surface. Form fitting structure configured as protrusions
preferably extend upward from the mounting surface or base and are
shaped in a manner that secures or constrains the individual
componentry.
[0013] The lattice structure is preferrably formed from a
thermoforming or an injection molding process. The openings need
not be of uniform dimension and are preferably of various optimal
or desirable sizes defined by irregular spacing between
cross-members and periphery members. Moreover, the openings may be
of any shape that is amenable to the components being assembled.
For example, a tray may have a series of rectangular openings, a
series of circular or elliptical openings, a combination of
rectangular and elliptical openings, or odd-shaped openings to
accommodate sets of or specific components.
[0014] Each tray has stacking structure, for example, support
columns that define the overall height of the tray on each of the
four corners of the tray. These columns allow the trays to be
stacked and laterally constrain each tray with respect to any
adjacent tray. The columns are configured so that the foot of the
column mate with the top of the column of the tray below when
stacked for example by male-female or other engaging structure.
[0015] An advantage of the present invention is the ease of both
loading and removing components from the inserts relative to the
pocket tray carrier. With conventional pocket carriers, personnel
are constrained by the side walls of the pockets, allowing access
only from the top of the pocket. Often, the constraints imposed by
a given pocket makes the grasping of components therein difficult,
both in the loading and in the assembly line phase. With the
present invention, the tray portion or insert can be readily
removed from the tray, where after an assembler can access the
components on the insert from all sides as well as from the top,
that is the fingers or pickup tool does not have to go into a
pocket. Moreover, a select portion after the insert has been loaded
or the component removed, the insert is readily placed back into
the tray.
[0016] Moreover, the removable trays allow different tray portion
sets configured to receive different component sets to be used in
the same framework. Additionally, the removable tray portions
create a modular system where individual parts of the trays may be
replaced or cleaned separate from the other parts. Moreover the
different components, that is the framework and plurality of tray
portions may be made of different materials. Additionally the
framework could be injection molded and the tray portions could be
vacuum formed.
[0017] Another advantage of preferred embodiments of the present
invention is that the protrusions that retain the components on the
inserts may be dimensioned so that the upper surfaces of the
components are at a uniform height when installed on the insert and
mounted in the tray. Thus, when a given tray is loaded with
components and stacked with other trays, the bottom surfaces of the
tray assembly above it serves as a cover that assures components
will not dislodge from the protrusions.
[0018] Still another advantage of preferred embodiments of the
present invention is that protrusions may also be more intricately
shaped for better retention of components. Thermoformed trays are
inherently non-intricate with respect to the profile of a given
protrusion. The preferred injection molding process of the present
invention is not so limited. Hence, the protrusions can be designed
to better capture components, making them less susceptible to
dislodgement or orientation changes during handling.
[0019] Another advantage of the various embodiments is that the
present invention, in the embodiments relating to injection molding
of the lattice structure or the tray portions provides a more
durable handling device with an expected longer life than the prior
art.
[0020] A further advantage of the present invention is that a
variety of unique insert configurations can be utilized in the same
lattice structure. The thermoformed trays of the prior art can be
loaded with only the components of a single disk drive. If one
minor change is required to just one of the pocket compartments,
the whole tray must be replaced. With the present invention, only
the insert that houses the modified component or layout need be
replaced.
[0021] Another advantage of the present invention is that the
assembly is less difficult to clean than the pocket tray design.
Pocket trays are prone to wash recirculation zones in the corners
of the pockets during the washing process. The present invention
can be configured to be free of pocketed geometries, resulting in
open surfaces that are easier to wash off.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a thermoformed pocket tray of the prior art;
[0023] FIG. 2 is an isometric projection of an assembled component
carrier tray according to the invention, as viewed from above;
[0024] FIG. 3 is an isometric projection of an assembled component
carrier tray according to the invention, as viewed from below;
[0025] FIG. 4 is an isometric projection of the invention with
inserts removed;
[0026] FIG. 5 is a cross-sectional view of an exemplary
cross-member;
[0027] FIG. 6 is an isolation view of an exemplary insert of the
invention;
[0028] FIG. 7 is an isolation view of an exemplary insert of the
invention;
[0029] FIG. 8 is an isolation view of an exemplary insert of the
invention;
[0030] FIG. 9 is an isolation view of an exemplary insert of the
invention;
[0031] FIG. 10 is an isolation view of an exemplary insert of the
invention with components mounted;
[0032] FIG. 11 is an isolation view of an exemplary insert of the
invention with components mounted;
[0033] FIG. 12 is an isolation view of an exemplary insert of the
invention with components mounted;
[0034] FIG. 13 is an isolation view of an exemplary insert of the
invention with components mounted;
[0035] FIG. 14 shows an embodiment of an assembled, unloaded
component carrier tray according to the invention;
[0036] FIG. 15 shows an embodiment of an assembled, loaded
component carrier tray according to the invention;
[0037] FIG. 16 shows a stack of loaded trays of the invention;
[0038] FIG. 17 shows a portion of a tray according to the
invention;
[0039] FIG. 18 shows a cross-sectional view of the FIG. 17
embodiment of the invention;
[0040] FIG. 19 shows a stack of trays in cross-section according to
the invention;
[0041] FIG. 20 shows an embodiment of the invention having circular
and elliptical openings.
DETAILED SPECIFICATION
[0042] An embodiment of the present invention in the form of a
component carrier tray 10 is shown in FIGS. 2-4. FIGS. 2 and 3
respectively show a top view and a bottom view of tray 10 in full
assembly, while FIG. 4 shows tray 10 without inserts. Tray 10 has a
framework 30 with peripheral members 31 and cross-members 40 that
create a lattice structure 20 having openings 50. Lattice structure
20 has an upper surface 120 that may be substantially planar. Frame
30 may have an integral skirt 55 that projects downward to define a
lower extremity 57 of tray 10. Tray 10 may be configured such that
the bottom surfaces 60 of cross-members 40 are flush with respect
to each other, thereby defining a registration plane 70. A
multiplicity of support structures 80 integral to bottom surfaces
60 project laterally from frame 30 and cross-members 40 such that
the upper surfaces (also referred to as registration surfaces 90)
of support structures 80 are also tangent to registration plane 70.
Support structures 80 may be such that they cantilever from a
single cross-member 40, or the support structures may span between
two cross-members 40 or between a cross-member 40 and frame 30, as
shown in FIG. 4.
[0043] A number of spacer or support columns 92 project upward from
frame 30 and terminate at an upper end 95. In this particular
embodiment, spacer columns 92 are located at the corners of frame
30, and are dimensioned and positioned so that when a second tray
is placed on top of a first tray, upper end 95 of a given spacer
column 92 fits within the boundaries of skirt 55 of the second tray
(see FIG. 14).
[0044] Referring to FIG. 5, the structural integrity of both the
cross-members and the support structures may be enhanced by
configuring cross-member 40 with a rib 45 that projects downward
from bottom surface 60 and below registration plane 70. While the
FIG. 5 embodiment depicts a hollow cross-member, cross-member 40
may also be solid.
[0045] A plurality of inserts 100 configured as tray portions are
seated within receiving regions configures as openings 50 of
lattice structure 20. In other embodiments some or all of the
receiving regions may be closed and be defined areas of the tray
framework. Tray portions 100 rest on registration surfaces 90 of
support structures 80. Referring to FIGS. 6-9, exemplary inserts
100 are shown in isolation. Each insert 100 has a perimeter 160 and
an upper or mounting surface 110 that, when seated in opening 50,
may be substantially flush with upper surface 120 of lattice
structure 20.
[0046] The embodiment of FIGS. 2-9 illustrate a number of ways to
secure inserts 100 to lattice structure 20. First, frame 30 and
each of cross-members 40 have a multiplicity of nubs 150 that
project slightly into openings 50. The nubs are dimensioned so that
when an insert 100 is placed into an opening 50, nubs 150 that are
in a given opening are in simultaneous and frictional contact with
perimeter 160 of insert 100. The frictional force thus generated
retains insert 100 within lattice structure 20. Alternatively,
insert 100 may be dimensioned to form an interference fit with
lattice structure 20 without use of nubs 150.
[0047] Another retention means is provided by a retention finger
structure 170 that works in conjunction with a clip 200. Retention
finger structure 170, located on one edge of a given opening 50, is
integral to or otherwise connected or bonded to upper surface 120
of lattice structure 20 and extends laterally over opening 150 such
that the lower surface of retention finger 170 is substantially
flush with upper surface 120 of lattice structure 20. Each insert
100 has a leading edge 180 that, when inserted into opening 50,
slides under retention finger structure 170. Opposite leading edge
180 of insert 100 is a trailing edge 190. Clip 200 is located near
trailing edge 190 of insert 100.
[0048] Referring to FIG. 9, clip 200 may be of an arcuate shape,
having a proximate portion 210 that is integral to and extends
upward from upper surface 110, and a distal portion 220 that
extends downward such that a free end 230 of the clip may extend
below insert 100. A barb 240 may be positioned on free end 230. To
install insert 100 within tray 10, leading edge 180 is first slid
under retention finger structure 170 so that leading edge 180 is in
contact with frame 30 or cross-member 40 from which retention
finger structure 170 projects. Then trailing edge 190 is lowered
into opening 50 until it registers on registration surfaces 90 of
the adjacent support structures 80. Clip 200 is dimensioned and
positioned so that barb 240 is in sliding contact with frame 30 or
cross-member 40 during the insertion, thereby deflecting clip 200
inward toward insert 100 as it is lowered into opening 50. As the
barb passes through registration plane 70, the force created by the
deflection of clip 200 causes barb 240 to snap into place and hook
the adjacent frame 30 or cross-member 40. This means of retention
secures the insert on two ends: by the retention finger structure
that extends over upper surface 110 on one end, and by engagement
of clip 200 on the other end. Clip 200 also serves as a handle for
assembly personnel to lift, control or otherwise manipulate insert
100.
[0049] To remove the insert with the illustrated embodiment, a
force is exerted on distal portion 220 that deflects clip 200
inward, so that barb 240 is released. Trailing edge 190 is then
lifted out of opening 150, and insert 100 is translated laterally
so that leading edge 180 is removed from under retention finger
structure 170.
[0050] Other embodiments may employ one or more of these retention
means, or none at all, depending on the retention requirements of
the application.
[0051] Inserts 100 may have a multiplicity of corner protrusions
250 that extend upward from upper surface 110 of insert 100, as
shown in FIGS. 6 and 7. Referring to FIGS. 10 and 11, corner
protrusions 250 are configured and spaced so as to loosely hold a
component 260 on its perimeter and in a fixed position. The corner
protrusions also elevate component 260 above mounting surface 110
of insert 100. The elevation allows an assembler to grasp component
260 easier. The elevation may also be sized so that upper faces or
extremities 270 of all components 260 are located on a same plane
that is substantially parallel upper surface 120 of lattice
structure 20 when tray 10 is fully loaded.
[0052] As shown in FIGS. 8, 9, 12 and 13, inserts 100 may
additionally or alternatively have a multiplicity of axial
protrusions 280 and grouped protrusions 290 that extend upward from
upper surfaces 110 of inserts 100. These protrusions also retain
components 260, but by a different means. Rather than securing
components 260 about their perimeter, protrusions 280, 290 either
pass through orifices on components 260, serve as receptacles that
grip appendages that extend from components 260, or simply provide
a pedestal that suspends a portion of component 260 above upper
surface 110 of insert 100. Axial and grouped protrusions 280, 290
can also be configured so that the suspension of components 260 is
such that their upper extremities 270 are substantially on the same
plane. Protrusions 250, 280 and 290 may both suspend and hold
component 260 in a preferred orientation.
[0053] Referring to FIGS. 14 and 15, a tray 11 that is another
embodiment of the present invention is shown, with unloaded and
loaded inserts, respectively. The particular embodiment shown is
designed to house the same components as the embodiment of FIGS. 2
through 13, but within a smaller footprint. Also, the embodiment
features a continuous extended skirt 310, as well as a continuous
ridge 320 that extends upward from frame 30 and encircles lattice
structure 20. When these trays are stacked, extended skirt 310 from
an upper tray and ridge 320 from a tray below may combine to
completely enclose components 260 of the lower tray. This
arrangement provides further protection of components 260 against
damage and serves as a barrier inhibiting particulate contamination
of components 260 when trays 11 are stacked. Alternatively, skirt
310 and ridge 320 may depend from other portions of lattice
structure 20 to encapsulate only certain components, or each
component individually. Where particulate contamination is of less
concern, skirt 310 or ridge 320 need not be continuous.
[0054] Referring to FIG. 16, a stack 300 of fully assembled and
loaded trays 11 is shown. Note how spacer columns 92 fit within
skirt 55, thus preventing tray 11 from sliding off spacer columns
92 of the tray below. A cross-section of a portion of the stack is
shown in FIGS. 17-19, which shows how a given tray in stack 300
serves as a retention lid and particulate barrier for the tray
below. Components 260 (shown in phantom), as previously discussed,
can be elevated on a given insert 100 so that upper faces 270 of
all components 260 on a given tray 11 are at the same elevation. In
the FIG. 16 embodiment, the elevation of upper faces 270 are such
that when a first tray assembly 12 is placed on spacer columns 92
of a second tray assembly 13, the bottom extremities of first tray
assembly 12 are just above or in slight contact with upper faces
270. Components 260 may thus be held in place during stacking and
relocation to temporary storage.
[0055] In some configurations, certain protrusions 281 pass through
or past components 260, as shown in FIG. 12. Such protrusions 281
thus extend above component 260. In such instances, protrusions 281
may be dimensioned so that first tray assembly 12 are just above or
in slight contact with protrusions 281. In this way, first tray
assembly 12 serves to cap protrusions 281, thereby capturing
components 260 without contacting the components. By utilizing the
tray above to hold components 260 in place, the various protrusions
250, 280 and 290 do not have to tightly grip the component;
instead, a loose fit will suffice. This makes removal of the
component easier during the assembly process.
[0056] Referring to FIG. 19, the present invention is not limited
to inserts 100 and openings 50 that are primarily rectangular in
shape. The FIG. 19 embodiment contemplates an insert 100 that is
circular or elliptical in shape, with cross-members 40 and frame 30
configured to accommodate the geometry of the inserts.
[0057] The use of the invention also gives rise to a new method of
using the various embodiments. The process starts with a tray that
is fully assembled, but bearing no components. The inserts may be
removed from the tray for the loading of components thereon. After
a given insert is loaded, it is placed in the appropriate tray
opening. This sequence is repeated until the desired inserts are
loaded. Once a tray is loaded for the purpose of assembly, it may
be stacked with other trays for dissemination on the assembly line
at a later time. Note that there is no need to cover the tray for
purposes of component retention.
[0058] At the appropriate time, trays may be placed sequentially on
an assembly conveyor for transport through the various assembly
phases. During assembly, assemblers may remove the inserts from the
trays to more readily access the components thereon. After
assembler has removed desired components, the insert is replaced in
the appropriate opening and the tray is put back onto conveyor for
transport to next assembly phase.
[0059] At end of the assembly phase, the trays, now containing
empty inserts, are collected. To minimize the risks associated with
particle contamination, the trays and inserts are preferably washed
in a detergent solution and rinsed. The trays and inserts may be
washed with inserts installed in the tray frane, or with the
inserts removed from the tray frame. Once the trays and inserts are
washed and rinsed, the trays are reassembled as necessary and
returned to the start of the process.
[0060] While the particular disk tray embodiments presented and
discussed in detail above are fully capable of obtaining the
objects and providing the advantages stated, it is to be understood
that they are merely illustrative of the present invention. Various
other modifications and changes with which the invention can be
practiced and which are within the scope of the description
provided herein will be readily apparent to those of ordinary skill
in the art.
* * * * *