U.S. patent application number 11/410793 was filed with the patent office on 2007-09-20 for tray for component packaging.
This patent application is currently assigned to FCI Americas Technology, Inc.. Invention is credited to Ronald P. Holler.
Application Number | 20070215517 11/410793 |
Document ID | / |
Family ID | 38516668 |
Filed Date | 2007-09-20 |
United States Patent
Application |
20070215517 |
Kind Code |
A1 |
Holler; Ronald P. |
September 20, 2007 |
Tray for component packaging
Abstract
A tray for component packaging that allows components having
varying heights to be automatically removed from the tray. The
packaging tray allows for all or most removal systems to function
regardless of the component height. The packaging tray includes a
base tray for holding a component and a removable spacer tray that
extends upward from the base tray to cover and protect the
component. During automatic removal of the component from the tray,
the spacer tray may be removed to reduce and/or minimize the
vertical lift travel required to remove the component from the
tray. The spacer tray may be left in place during the removal
process and is constructed to allow removal of the component. The
spacer tray may provide a top surface that is substantially flush
with the top of the component and may be left in place during the
removal process for removal systems that require that the over
sized (height) components be substantially flush with the top
surface of the tray during removal from the tray.
Inventors: |
Holler; Ronald P.;
(Mechanicsburg, PA) |
Correspondence
Address: |
WOODCOCK WASHBURN, LLP
CIRA CENTRE, 12TH FLOOR
2929 ARCH STREET
PHILADELPHIA
PA
19104-2891
US
|
Assignee: |
FCI Americas Technology,
Inc.
Reno
NV
|
Family ID: |
38516668 |
Appl. No.: |
11/410793 |
Filed: |
April 25, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60782777 |
Mar 16, 2006 |
|
|
|
Current U.S.
Class: |
206/725 ;
206/561; 206/562 |
Current CPC
Class: |
H01L 21/67333
20130101 |
Class at
Publication: |
206/725 ;
206/561; 206/562 |
International
Class: |
B65D 85/00 20060101
B65D085/00; B65D 1/34 20060101 B65D001/34 |
Claims
1. A tray for component packaging comprising: a base tray having a
base tray height that is less than a height of a component
contained within said base tray; a spacer tray mounted on top of
said base tray, said spacer tray having a spacer tray height; an
overall tray height comprising at least a portion of said base tray
height and at least a portion of said spacer tray height, wherein
said overall height extends flush with or above a top of said
component contained with in said tray; wherein said component may
be removed from said tray either with said spacer tray removed from
said base tray and/or with said spacer tray in place on said base
tray.
2. The tray of claim 1, wherein said spacer tray is removable and
is removed from said base tray prior to removal of said component
from said base tray, wherein said removal of said spacer tray
reduces an effective lift travel required to remove said component
from said base tray.
3. The tray of claim 1, wherein said spacer tray is left in place
on said base tray during removal of said component from said base
tray, wherein a top surface of said spacer tray is used as a
reference for removal of said component from said tray.
4. The tray of claim 1, wherein said base tray further comprises: a
bottom portion; a periphery wall extending around and generally
upward from said bottom portion; one or more interior walls
extending generally upward from said bottom portion and extending
between opposite walls of said periphery wall; a plurality of base
pockets formed by one or more of said periphery wall and/or said
one or more interior walls, each of said base pockets comprises a
base pocket height; an open end of each pocket defined by distal
ends of one and/or more of said periphery wall and said one or more
interior walls; wherein said spacer tray further comprises: a top
portion; a periphery wall extending around and generally downward
from said top portion; one or more beams extending between opposite
walls of said spacer tray periphery wall; a plurality of spacer
pockets formed by one or more of said spacer tray periphery wall
and/or said one or more beams, each of said spacer pocket
comprising a spacer pocket height; and a pocket comprising said
base pocket and said spacer pocket, said pocket having an overall
pocket height comprising at least a portion of said base pocket
height and at least a portion of said spacer pocket height; wherein
said overall pocket height is flush and/or slightly above a top of
said component seated in said pocket.
5. The tray of claim 4, wherein said spacer tray further comprises
a plurality of openings defined by one or more of said spacer tray
periphery wall and/or said beams, wherein said spacer tray openings
correspond to and are aligned over said open ends of said based
tray pockets, wherein said spacer tray openings are sized to allow
removal of said component from said pocket.
6. The tray of claim 1, wherein said spacer tray is adapted to be
left in place for use with automated component removal systems
having adequate vertical lift travel available to clear a top of
said spacer tray, wherein one of said components may be lifted from
said pocket and removed from said tray through an opening in said
spacer tray; and wherein said spacer tray is adapted to be removed
from said base tray for use with automated component removal
systems having inadequate vertical lift travel available to clear a
top of said spacer tray but that do have adequate vertical lift
travel available to clear a top of said base tray once said spacer
tray has been removed from said base tray, wherein one of said
components may be lifted from said base pocket and removed from
said base tray.
7. The tray of claim 1, wherein said base tray comprises base
pockets having standard base pocket sizes and wherein said spacer
tray comprises spacer pockets having varying spacer pocket sizes,
wherein said varying spacer pocket sizes provide for storage of
different height components within said tray and allows said tray
to be used with automated pick and place systems having varying
vertical lift travel.
8. The tray of claim 1, wherein multiple trays may be stacked one
on top on another, wherein a bottom portion of said base tray of a
vertically upward successive tray stacked on top of a spacer tray
of a vertically downward successive tray covers over openings in a
top portion of said spacer tray upon which said vertically upward
successive base tray is stacked.
9. The tray of claim 8, wherein said trays further comprise an
engagement mechanism disposed between adjacent trays for holding
said trays with respect to one another in both a vertical and
horizontal direction.
10. The tray of claim 1, wherein said tray further comprises a
component orientation feature in said base pocket, wherein said
orientation feature of said base pocket are aligned with
corresponding orientation feature on said component to be stored in
said pocket to ensure proper orientation of one of said components
within each of said pockets.
11. The tray of claim 1, wherein said base tray further comprises:
a recess in a bottom portion of said base pocket; and a shelf
formed around a perimeter of said recess; wherein terminal ends
extending from a housing of said component may extend into said
recess and said component housing may engage said shelve.
12. The tray of claim 1, wherein said tray further comprises:
component positioning features located in corner areas of each of
said pockets; wherein said component positioning features provide
point contact of said component within said pocket for improved
positioning of one of said components within each of said
pockets.
13. The tray of claim 1, wherein said tray further comprises an
engagement mechanism disposed between said base tray and said
spacer tray for holding said spacer tray and said base tray with
respect to one another in both a vertical and horizontal direction,
wherein said engagement mechanism further comprises: a base tray
shelf formed on an upper, outer portion of said base tray
peripheral wall, said base tray shelf comprising a vertical portion
and a horizontal portion; and a spacer tray shelf formed on a
lower, inner portion of said spacer tray peripheral wall, said
spacer tray shelf comprising a corresponding vertical portion and
horizontal portion that contacts and engages said base tray
vertical and horizontal portions.
14. The tray of claim 1, wherein said component further comprises a
surface mount technology component designed to be applied to a
mounting surface.
15. A multiple part packaging tray comprising: a base tray having a
plurality of pockets, wherein each pocket is adapted to receive and
for hold a component; a spacer tray mounted on top of said base
tray, wherein a top of said spacer tray is substantially flush with
a top of said component, wherein said spacer tray covers and
protects said components when said spacer tray is mounted on said
base tray; wherein spacer tray is adapted to be either: removed
from said base tray during removal of said components from said
multiple part packaging tray, wherein removal of said spacer tray
accommodates varying lift travel available for removing components
having different heights out of said multiple part packaging tray,
wherein removal of said spacer tray reduces an effective lift
travel required to remove said components from said base tray; or
left in place on said base tray during removal of said components
from said multiple part packaging tray, wherein said spacer tray
accommodates location of said components by reference to said
spacer tray.
16. The multiple part packaging tray of claim 15, wherein said base
tray height is minimized with respect to a height of said
components to reduce vertical lift travel required to lift and
remove said components from said base tray.
17. The multiple part packaging tray of claim 15, wherein said base
tray further comprises: a standard height of a base pocket that is
less than a height of said component; a recess in a bottom of each
base pocket, wherein each recess provides a clearance between a
bottom portion of said component and said bottom of said recess;
said spacer tray further comprises: a height of said spacer tray
that varies based on a height of said components packaged in said
tray; wherein said spacer tray height is sufficient to ensure that
a top surface of said spacer tray is slightly above a top of said
components in said pockets.
18. The multiple part packaging tray of claim 15, further
comprising: a plurality of pockets in said tray, wherein each
pocket holds one component; a plurality of openings in a top
portion of said spacer tray, wherein said openings correspond and
are aligned above said pockets; wherein components may be removed
through said openings in said spacer tray while said spacer tray is
mounted on said base tray.
19. The multiple part packaging tray of claim 18, further
comprising a plurality of multiple part packaging trays staked one
on top of another, wherein each vertically successive base tray
covers said openings in an adjacent spacer tray upon which said
base tray is stacked.
20. A method of packaging a surface mount component designed to be
applied to a mounting surface, said method comprising: providing a
base tray having a plurality of base pockets for receiving a
component, wherein said base tray pockets comprise a base pocket
height that is less than a height of said components to be stored
in said base pockets; mounting a spacer tray on top of said base
tray to cover said components, wherein said spacer tray comprises a
top surface that is flush with or slightly above a top of said
components; providing openings in said top surface of said spacer
tray, wherein said openings are sized to allow removal of said
components from said pockets; wherein said method of packaging
addresses multiple pick and place equipment needs by: removing said
spacer tray prior to placement of said packaging tray in said pick
and place equipment, wherein removing of said spacer tray reduces
an effective vertical lift travel required to remove said component
from said base tray; and/or leaving said spacer tray in place on
said base tray during placement of said packaging tray in said pick
and place equipment, wherein leaving said spacer tray in place
provides a reference point for said pick and place equipment to
located said components to be removed.
Description
RELATED APPLICATION
[0001] The subject matter disclosed herein is related to the
subject matter disclosed in Provisional U.S. Patent Application
having Ser. No. 60/782,777, filed Mar. 16, 2006, entitled "Tray For
Component Packaging"; which is assigned to the assignee of the
present application and hereby incorporated herein by reference in
its entirety.
FIELD OF THE INVENTION
[0002] Generally, the invention relates to trays for component
packaging. More particularly, the invention relates to a packaging
tray constructed in multiple parts to accommodate varying lift
travel available for removing components from the tray. This
technology is particularly suited, but by no means limited, for
holding surface mount components designed to be applied to a
mounting surface.
BACKGROUND OF THE INVENTION
[0003] Surface mount components may be applied to printed circuit
boards through automated equipment. This equipment is typically
referred to as pick and placement equipment and may be fully
automated requiring components to be packaged with the means for
automated handling.
[0004] Trays are one common type of packaging used for automated
handling of components. There exists a problem as components get
larger that some placement equipment have limitations on the amount
of travel available to lift a component out of a tray. Also, in
order to improve component placement time, it is desirable to
reduce the lift travel required to remove a component from the
tray. In addition, problems exists in that certain automated
handling equipment can not handle trays having different size
pockets for holding components having varying heights due to
limited available lift travel. It is desirable to have a standard
component packing tray having a standard lift travel that may be
used with a plurality of automated component handling systems.
[0005] Trays for the storage and transportation of multiple pin
grid array (PGA) integrated circuit components are known. The
approach disclosed in U.S. Pat. No. 5,103,976, for example,
includes a tray having a lattice of framework defining discrete
storage pocket areas. Each storage pocket area includes a base
support spanning a portion of the framework and upstanding ribs
that engage the integrated circuit component. Depending pins of the
integrated circuit components lie between individual upstanding
ribs. In addition, providing a spacer tray for stacking multiple
storage trays having integrated circuits is also known. U.S. Pat.
No. 5,335,771, for example, discloses a system for storing
integrated circuits in a stacked relationship comprising integrated
circuit storage trays and spacer trays. Each integrated circuit
storage tray has a storage pocket area for containing an integrated
circuit. When portions of the integrated circuit protrude beyond
the overall profile of the storage tray, a spacer tray can be
interposed between adjacent storage trays. The spacer tray elevates
an adjacent storage tray to clear the protruding portions of the
integrated circuit. The integrated circuit storage trays disclosed
in U.S. Pat. No. 5,103,976 and U.S. Pat. No. 5,335,771, however, do
not address multiple pick and place equipment needs concerning the
height of the product stored in each individual storage pocket.
[0006] In another approach, disclosed in U.S. Pat. No. 5,957,293, a
dual-purpose tray is provided for packing and shipping of
semiconductor integrated circuit devices, such as a plurality of
ceramic substrates and/or ceramic ball grid array (BGA) packages.
Individual pockets on the tray are defined by a bottom wall and
side walls. Each pocket includes stand-offs and semi-circular
depressed support members. When trays are stacked, the stand-offs
and support members act as a retention mechanism that functions to
retain and hold devices in the pocket and prevent the devices from
being displaced from the pockets. The trays disclosed in U.S. Pat.
No. 5,957,293 require a common tray design for all trays used in
the industry by many manufacturers and do not address multiple pick
and place equipment needs concerning the height of the product
stored in each individual storage pocket.
[0007] In yet another approach, disclosed in U.S. Patent
Application Publication US 2005/0133404 A1, a tray having three
dimensionally adjustable sized pockets for holding a plurality of
electronic components is provided. Interlocking longitudinal and
transverse dividers are positioned in a tray base cavity to form a
rectangular array having a plurality of rectangular pockets. The
lengths and widths of the pockets are adjustable by selecting a
particular divider notch for intersection of each longitudinal and
transverse divider. A rectangular top frame of selected thickness
is positioned over the wall notches to retain the dividers, and to
define a height of each pocket upon placing a lid over the tray.
This approach also fails to address the concerns relating to
multiple pick and place requirements on height of parts found in
all or most existing pick and place equipment.
SUMMARY OF THE INVENTION
[0008] In general, one aspect of the present invention is to use a
component packaging tray constructed in multiple pieces to
accommodate varying lift travel available to lift components having
different heights out of the tray and onto a mounting surface of,
for example, a printed circuit board.
[0009] Constructing the packaging tray in multiple parts allows the
packaging tray to be loaded in the placement equipment with or
without the spacer tray, thereby accommodating varying lift travel
of the placement equipment.
[0010] This design makes it possible for placement equipment with
limited available lift travel to operate by having the tray
constructed in multiple components. A base that holds the part and
is design to allow a part to be lifted out of the based with the
lift available on the placement equipment and a spacer tray that
extends from the base up around the part to protect the part and to
make it possible for the trays to be stacked on top of one
another.
[0011] The component packaging tray preferably minimizes the
vertical lift travel required to remove a component from the tray.
The tray for component packaging addresses multiple pick and place
equipment needs concerning the height of the product stored in each
individual storage pocket. The tray for component packaging
preferably fits a plurality of pick and place systems.
[0012] For equipment with limited lift travel the spacer tray can
be removed and the tray can be introduced to the placement
equipment. When the spacer tray is removed, the lift travel
required to remove the component from the tray is
reduced/minimized. Reduced lift travel helps improve placement time
and efficiencies.
[0013] The tray can be used with the spacer tray in place for
equipment with no lift travel inadequacies. The tray with the
spacer tray left in place during the removal process may also be
used for equipment that require that over sized (height) components
be substantially flush with the top surface of the tray for the
removal system to function properly.
[0014] According to another aspect of the invention, a tray for
component packaging includes a multi-piece design and construction
including a base tray and a spacer tray. The base tray includes a
bottom portion, a peripheral wall extending around and upward from
the bottom portion, one or more interior walls extending upward
from the bottom portion and extending between opposite walls of the
peripheral wall, a plurality of pockets on the base tray, and open
ends of the pockets defined by distal ends of one of more of the
peripheral wall and one or more of the interior walls. The spacer
tray includes a top portion, a peripheral wall extending around and
downward from the top portion, one or more beams extending between
opposite walls of the peripheral wall, and a plurality of openings
defined by one or more of the peripheral wall and the beams. The
spacer tray openings correspond to and are aligned over the open
ends of the base tray pockets.
[0015] The base tray may have a standard height that is less than a
height of a component that may be disposed in the pocket. The
spacer tray may have a height that is determined by the height of
the components that is disposed in the pockets.
[0016] In one currently preferred embodiment, the packaging tray
comprises a base tray having a relatively shallow pocket for
receiving and holding an electrical connector, such as a Gig-array
electrical connector. The height of the electrical connector may be
greater than the height of the pocket in the base tray. A spacer
tray may be disposed over the base tray and acts to extend the
pocket to cover and protect the electrical connector. The packaging
tray may be used to accommodate automatic handling of the
electrical connectors for placement on a mounting surface, such as
for example, a printed circuit board.
[0017] Another aspect of the invention includes a method of
accounting for limited lift travel by providing a tray having a
base tray and a removable spacer tray that may be left in place for
use with automated removal equipment with sufficient lift travel
for components stored in the tray, and that may be removed for use
with automated removal equipment with insufficient lift travel for
components stored in the tray.
[0018] Additional features and advantages of the invention will be
made apparent from the following detailed description of
illustrative embodiments that proceeds with reference to the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention is best understood from the following detailed
description when read in connection with the accompanying drawing.
Included in the drawings are the following Figures that show
various exemplary embodiments and various features of the present
invention:
[0020] FIG. 1 is an exploded perspective view of an exemplary tray
for component packaging;
[0021] FIG. 2 is a partial cross-sectional view of a pocket of FIG.
1 holding an exemplary component and showing the engagement of the
base tray and the spacer tray;
[0022] FIG. 3 is a partial cross-sectional view of the pocket
holding the component of FIG. 2 showing the spacer tray removed and
the reduced lift travel required to remove the component from the
pocket;
[0023] FIG. 4 is an exploded perspective view of another exemplary
tray for component packaging;
[0024] FIG. 5 is a partial cross-sectional view of the pocket of
FIG. 4 holding another exemplary component and showing the
engagement of the base tray and the spacer tray;
[0025] FIG. 6 is a partial cross-sectional view of the pocket
holding the component of FIG. 5 showing the spacer tray removed and
the reduced lift travel required to remove the component from the
pocket;
[0026] FIG. 7 is a partial cross-sectional view of the pocket
holding the component of FIG. 5 and showing an exemplary pick and
place system;
[0027] FIG. 8 is a partial cross-sectional view of the pocket
holding the component of FIG. 7 showing the spacer tray removed and
the reduced lift travel required to remove the component from the
pocket;
[0028] FIG. 9 is an exploded view illustrating the trays for
component packaging being stackable; and
[0029] FIG. 10 shows an exemplary pick and place tray rack.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0030] The present invention is directed to trays for component
packaging. The packaging tray 1 may be constructed in multiple
pieces to accommodate varying lift travel available to lift
components 50 having different heights out of the packaging tray 1.
This multiple part design makes it possible for handling and/or
placement equipment 70 with limited available lift travel to
operate by having a removable spacer tray 30 disposed over a base
tray 10. The base tray 10 holds the component 50 and is designed
and constructed to reduce and/or minimize the lift travel required
to lift the component out of the base tray 10. The spacer tray 30
extends from the base tray 10 up and around the component 50 to
protect the component 50 and to allow trays 1 to be stacked on top
of one another.
[0031] This concept of a multi-piece packaging tray 1 applies to
applications wherein lift travel available may be inadequate to
lift the component from the tray 1. This concept of a multi-piece
packaging tray 1 also applies to applications that use handling
and/or placement equipment 70 that may have sufficient lift travel,
but wherein the application desires improved assembly or
manufacturing time. Component assembly or manufacturing time may be
improved by removing the spacer tray 30 from the base tray 10
thereby reducing the lift travel and hence reducing the time
required to lift the component 50 from the packaging tray 1. The
multi-piece packaging tray 1 may also find use in applications that
may require placement of different height components but that have
equipment having a set or standard lift travel. The base tray 10
can have a set or standard height and the removable spacer tray 30
can be used to account for the varying component height. Also, the
multi-piece packaging tray 1 can be used for applications having
placement equipment 70 that operates by sensing the top of the tray
1. The spacer tray 30 may be sized to be flush or slightly above
the top of the component 50.
[0032] Various embodiments of a tray for component packaging 1 are
shown and described, including a packaging tray 1 having a
relatively low or short component 50, as shown in FIGS. 1-3, and a
packaging tray 1 having a relatively high or tall component 50, as
shown in FIGS. 4-6. As shown, the packaging tray 1 has an overall
height H1 that includes a combination of the assembled base tray 10
and spacer tray 30. The height H1 of the assembled packaging tray 1
is preferably sufficient to cover a component 50 contained within
the packaging tray 1.
[0033] The base tray 10 may include a base tray height H2 and the
spacer tray 30 may include a spacer tray height H3. In certain
embodiments, the base tray height H2 may include a set or constant
height and the spacer tray height H3 may include a variable height.
As shown in FIGS. 2 and 5, the height of the spacer tray H3 may
varying depending on the height of the component 50 held in the
packaging tray 1. The spacer tray 30 may have a height H3 that
generally corresponds to the height of the component 50 contained
with the tray 1--i.e., when the spacer tray 30 is installed on the
base tray 10 the top of the spacer tray 30 preferably covers the
components stored in the packaging tray 1. Generally, for
embodiments having a base tray having a constant height H2, the
height of the spacer tray H3 increases as the height of components
50 contained within the packaging tray 1 increases.
[0034] For example, the component 50 shown in FIGS. 4-6 is taller
than the component 50 shown in FIGS. 1-3. In the illustrated
embodiments, the height of the base tray H2 in FIGS. 1-6 is
substantially the same, but the height of the spacer tray H3 in
FIGS. 4-6 is greater than the height of the spacer tray H3 in FIGS.
1-3.
[0035] The base tray 10 holds one or more components 50. The spacer
tray 30 extends from the base tray 10 to cover the component 50. As
such, the spacer tray 30 extends the effective height of the tray 1
to cover and protect the component 50 during, for example, shipment
and storage. As shown in FIGS. 2 and 5, the spacer tray 30 in
combination with the base tray 10 includes lift travel LT1 that
varies as the height of the components 50 stored in the packaging
tray 1 varies. As the height of the component 50 increases, the
height of the spacer tray 30 increases, and hence the height of the
lift travel LT1 increases. Lift travel LT1 is the distance that the
component 50 seated within the base tray 10 must be lifted in order
to clear the top portion 31 of the spacer tray 30.
[0036] During removal/placement of the component 50, the spacer
tray 30 may be removed from the base tray 10 thereby reducing the
effective lift travel required to remove the component 50 since the
component 50 only has to clear the height of the base tray 10 (see
FIGS. 3 and 6) and not the combined height of the base tray 10 and
the spacer tray 30 (see FIGS. 2 and 5).
[0037] As shown in FIGS. 3 and 6, the base tray 10 includes a
relatively low base tray lift travel LT2--i.e., the base tray lift
travel required to remove a component with the spacer tray 30
removed is generally less than the height of the component 50. The
base tray 10 may include a standard or set base tray lift travel
LT2 that is substantially the same regardless of the height of the
various components 50 that may be stored in the packaging tray 1.
Having a set and relatively low base tray lift travel LT2 provides
a packaging tray 1 that helps facilitate standardization and
minimization of lift travel between different pick and place
systems 70. The base tray lift travel LT2 is the distance that the
component 50 seated within the base tray 10 must be lifted in order
to clear the top portion 11 of the base tray 10. Depending on the
particular component to be packaged and the particular application,
the base tray 10 may include a standard size, and/or a series of
standard sizes, and/or non-standard sizes.
[0038] For placement equipment 70 with no lift travel inadequacies,
the packaging tray 1, including the combination of the base tray 10
and the spacer tray 30 holding the components 50, may be introduced
to the placement equipment 70, as shown in FIG. 7. For placement
equipment 70 with limited available lift travel, the spacer tray 30
can be removed before the packaging tray 1 is introduced to the
placement equipment 70. As such, the packaging tray 1, including
the base tray 10 holding the components 50, may be introduced in to
the placement equipment 70, as shown in FIG. 8.
[0039] The tray for component packaging 1 also provides value for
use in pick and place systems 70 having time constraints and/or
systems seeking improved efficiencies. A greater lift travel
generally increases the component removal/placement time. The
packaging tray 1 with a removable spacer tray 30 that has been
removed prior to insertion of the tray 1 in to a placement system
70 reduces the effective lift travel resulting in a reduced lift
travel and an improved component removal/placement time (assuming a
constant speed). This helps provide manufacturing and cost
benefits.
[0040] The tray for component packaging 1 may address multiple pick
and place equipment needs concerning the height of the product or
component 50 stored in the packaging tray 1. The packaging tray 1
preferably fits a plurality of pick and place systems 70 and
minimizes and/or reduces the vertical lift travel required to
remove a component from the tray 1 to a height that is less than
the height of the component 50.
[0041] FIGS. 1-6 show an exemplary tray 1 for component packaging.
As shown, the multi-piece tray 1 includes a base tray 10 and a
spacer tray 30. FIGS. 1-6 also show a component 50 stored in
packaging tray 1.
[0042] As shown in FIGS. 1-6, the base tray 10 includes a bottom
portion 11 and a peripheral wall 12. As shown, the peripheral wall
12 may extend around the perimeter of the bottom portion 11 and may
extend generally upward from the bottom portion 11. Interior walls
13 extend generally upward from the bottom portion 11. As shown,
the interior wall 13 may include one or more longitudinal walls 13a
and/or one or more transverse walls 13b that extend between
opposite sides of the peripheral wall 12.
[0043] A plurality of pockets 14 may be formed by the peripheral
wall 12 and/or interior walls 13. The pockets 14 include an open
end 15 formed by the distal ends of the peripheral wall 12 and/or
the interior walls 13. The plurality of open ends 15 of the pockets
14 may form an array.
[0044] The pocket or cavity 14 preferably includes features that
facilitate receiving, storing, and removing components 50. For
example, the pockets 14 may include a chamfered edge 16. The pocket
14 may also include an orientation feature 17. For example, the
orientation features may include lugs 17 that help ensure that the
component 50 is properly oriented and positioned in the pocket 14.
The pocket 14 may also include cut-outs 18 in one or more interior
walls 13 to facilitate manual removal of a component 50 from pocket
14. The pockets 14 may include a shelf 19a and a recess 19b. As
shown, the shelf 19a contacts and engages a bottom 52 of the
housing 51 of the component 50 and the recess 19b receives, for
example, contacts 55 extending from the component. In the
illustrated embodiment, the recess 19b may receive solder
balls/tails 55 extending from of an electrical connector 50 stored
in pocket 14.
[0045] The pockets 14 may also include part positioning features
25. The part positioning features 25 are shown at the corner areas
of each pocket 14. The part positioning features 25 provide point
contact of the component 50 within each pocket 14 for improved
positioning of the component 50 in pocket 14. The part positioning
features 25 help ensure more accurate positioning of component 50
and reduce the potential of bowing and/or warping of the tray 1 or
component 50. The part positioning features 25 may be formed as a
build up of material on the peripheral wall 12 and/or interior
walls 13 proximate the corner area of each pocket 14 and/or as a
cutout of material in the center region of each wall of each pocket
14.
[0046] As shown, the bottom portion 11 of the pockets 14 are shown
as solid bottoms. Forming the bottom portion 11 of the pockets 14
as a solid piece helps to protect the component 50 contained within
the pocket 14 from damage and/or contamination. For example, if the
component 50 is an electrical connector, a pocket 14 having a solid
bottom portion 11 helps protect the solder balls 55 from damage
and/or dirt. In another embodiment (not shown), openings may be
formed in the bottom portion of each pocket. Forming openings in
the bottom portion of each pocket may result in material and cost
savings.
[0047] In one embodiment, the base tray 10 is tooled to JDEC
Specification 95-1. Preferably, the base tray 10 is formed of a
plastic, although other suitable materials may be used.
[0048] As shown, the spacer tray 30 includes a top portion 31 and a
peripheral wall 32. Preferably, the top portion 31 is flush with or
slightly above the top of a component 50 seated in a pocket 14. As
shown, the peripheral wall 32 of the spacer tray 30 may extend
around the perimeter of the top portion 31 and extend generally
downward from the top portion 31. As shown, interior beams 33
extend between opposite sides of the peripheral wall 32. The beams
33 may include one or more longitudinal beams 33a and/or one or
more transverse beams 33b. In an alternate embodiment (not shown),
the interior beams 33 of the spacer tray 30 may include interior
walls that extend generally downward from the top portion 31.
[0049] A plurality of openings 34 may be formed by the peripheral
wall 32 and/or interior beams 33 of the spacer tray 30. The
openings 34 of the spacer tray 30 preferably correspond to and are
positioned above to the open ends 15 of the pockets 14. The
plurality of openings 34 may form an array corresponding to the
array formed by the open ends 15 of the pockets 14.
[0050] As shown in the Figures, the component 50 may include a
housing 51 having a bottom 52, a top 53, sidewalls 54. The bottom
52 may contact and be supported by the bottom portion 11 of the
base tray 10. As shown, the component 50 may sit on a shelf 19a
formed in the bottom portion 11 of the base tray 10. The component
50 may include contact terminal ends, such as solder balls/tails 55
that extend into a recess 19b in the bottom portion 11. The side
walls contact and engage the part positioning feature 25 on the
pocket 14. The component 50 may also include a pick-up cap 56.
[0051] The component 50 may include an orientation feature 57 that
corresponds to the orientation feature 17 in pocket 14 of packaging
tray 1. For example, the component housing 51 may include a cavity
57 for receiving lug 17. In addition, the side walls 54 of
component 50 may contact the chamfered edge 16 of pocket 14 to
facilitate insertion and removal of the component 50 in to and out
of pocket 14.
[0052] The tray 1 for component packaging is particularly suited,
but by no means limited, for holding surface mount technology (SMT)
products designed to be applied to a mounting surface. For example,
the tray for component packaging 1 may hold an electrical
connector, chips, integrated circuits, ball grid array (BGA), and
the like designed to be applied to printed circuit boards (PCB). In
one embodiment, the component may include a Gig-Array electrical
connector manufactured by FCI, Inc. In an exemplary Gig-Array
electrical connector, the component height may vary between about
10 mm and about 35 mm. Although a single component 50 is shown in
FIGS. 1-6, it should be appreciated that the packaging tray 1 may
contain multiple components.
[0053] The components stored in tray 1 may include various
stack-height options to enable the component to address various
component requirements, such as clearance, airflow, slot spacing,
etc. that may be unique to the component's chassis design.
Applications that may benefit from the multi-piece packaging tray 1
include electronics, servers, communications, telecommunications,
switching equipment, networking equipment, computer systems, and
the like.
[0054] As shown in the Figures, the base tray 10 includes a base
tray height H2, which preferably includes a relatively shallow base
pocket having a pocket height 14a. For example, as shown in the
Figures the pocket height 14a in base tray 10 is preferably less
than the height of the component 50 that may be stored within the
base tray 10. The height of the base pocket 14a is measured from
the lowermost portion to an uppermost portion of the base
pocket.
[0055] The height of the spacer tray H3 preferably varies based on
the height of the component that is stored in the packaging tray 1.
Preferably, the spacer tray 30 includes a spacer pocket having a
pocket height 14b. In embodiments wherein the packaging tray 1
includes components having a relatively low height, such as the
exemplary embodiment shown in FIGS. 1-3, the packaging tray 1 may
include a spacer tray 30 having a relatively low peripheral wall 32
and having a relatively low spacer tray height 14b. Alternatively,
in embodiments wherein the packaging tray 1 includes components
having a relatively high height, such as the exemplary embodiment
shown in FIGS. 4-6, the packaging tray 1 may include a spacer tray
30 having a relatively high peripheral wall 32 and having a
relatively high spacer tray height 14b.
[0056] When the spacer tray 30 is stacked on the base tray 10, the
combination of the base pocket height 14a and the spacer pocket
height 14b form an overall pocket height 14c. The overall pocket
height 14c is preferably sufficient to receive and cover the
component 50 received within the pocket 14. The top of the overall
pocket height 14c is preferably flush or slightly above the top 53
of the component 50 seated in the pocket 14.
[0057] The lift travel height LT1 or LT2 is substantially equal to
the distance from the lowest most portion of the component 50 to
the top of pocket 14. The top of pocket 14 can include the top of
the spacer plate 30 (represented by LT1) or, in embodiments wherein
the spacer tray 30 is removed, the top of the base tray 10
(represented by LT2). The lift travel height LT1/LT2 is the
distance from the lowermost portion of the component (i.e., solder
balls 55) to the top portion of either the spacer tray 30, such as
shown in FIG. 7, and/or the base tray 10, such as shown in FIG.
8.
[0058] In the embodiment shown in FIG. 7, wherein the packaging
tray 1--including the base tray 10 and the spacer tray 30--is
inserted in to a placement system 70, the lift travel. Lt1 required
to remove the component from the packaging tray 1 must clear the
top of the spacer tray 30. In the embodiment shown in FIG. 8,
wherein the packaging tray 1--including the base tray 10--is
inserted in to a placement system 70, the lift travel LT2 required
to remove the component from the packaging tray 1 only has to clear
the top of the base tray 10.
[0059] As shown in FIGS. 1-6, the packaging tray 1 preferably
includes an engagement mechanism for holding the spacer tray 30
with respect to the base tray 10. Preferably, the engagement
mechanism is disposed between the base tray 10 and the spacer tray
30 and helps to orient and hold the spacer tray 30 with respect to
the base tray 10 in the vertical and horizontal direction.
[0060] As shown, the engagement mechanism may include a shelf or
seat 20 on the base tray and a corresponding shelf or seat 40 on
the spacer tray. As shown in the exemplary embodiment, the base
tray shelf 20 is formed on an upper, outer portion of the
peripheral wall 12 and includes a vertical portion 20a and a
horizontal portion 20b that contact and engage a corresponding
vertical portion 40a and horizontal portion 40b on a lower, inner
portion of the spacer tray shelf 40. The engagement of the
horizontal portions 20b and 40b help to maintain the vertical
engagement between the base tray 10 and the spacer tray 30, and
vertical portions 20a and 40a help to maintain the horizontal
engagement between the base tray 10 and the spacer tray 30.
[0061] Preferably, the base tray 10 and the spacer tray 30 are
constructed to make it possible for multiple trays to be stacked
vertically one on top of another. FIG. 9 illustrates that multiple
trays 1 may be stacked together. When multiple trays 1 are stacked
together, the bottom of the above tray may function as a lid to
hold in place the components in the below adjacent tray.
[0062] In addition to the engagement mechanism between the base
tray 10 and the spacer tray 30 of individual trays 1a, 1b, another
engagement mechanism may be provided between adjacent trays 1a, 1b.
For example, an engagement mechanism may be provide between the
spacer tray 30a of a first tray 1a and the based tray 10b of an
adjoining tray 1b that may be stacked on top of tray 1a. This
second engagement mechanism facilitates stacking of tray 1b on top
on tray 1a. As shown, the engagement mechanism may be disposed
between the spacer tray 30a and base tray 10b and helps to stack,
orient, and hold trays 1a and 1b with respect to one another.
[0063] Preferably, the second engagement mechanism between
adjoining trays 1a, 1b holds adjoining trays with respect to one
another in the vertical and horizontal direction. As shown, the
second engagement mechanism between trays 1a and 1b may include a
shelf or seat 21 on the upper, outer portion of spacer tray 30a and
a corresponding shelf or seat 41 on the lower, inner portion of
base tray 10b. As shown, the spacer shelf 21 on spacer tray 30a
includes a vertical portion 21a and a horizontal portion 21b that
contact and engage corresponding vertical portion 41a and
horizontal portion 41b on the base tray 10b. The engagement of the
horizontal portions 21b and 41b help to maintain the vertical
engagement between tray 1a and tray 1b, and vertical portions 21a
and 41a help to maintain the horizontal engagement between tray 1a
and tray 1b.
[0064] Pick and place systems are designed to perform repetitive
picking and placing tasks in production or laboratory facilities,
and are usually employed for their precision and cost effectiveness
and can be used with the present invention to remove the component
50 from tray 1. Preferably, the trays for component packaging 1 may
be used with a variety of pick and place systems to satisfy a
particular application. Pick and place machines may offer
efficiency and precision, resulting in an increase in output as
well as long-term savings. In one preferred embodiment, the pick
and place system includes an electrical connector placement
platform that offers a combination of high-speed placement,
repeatability, scalability, and flexibility.
[0065] As shown in FIGS. 7 and 8, an exemplary pick and place
system 70 may include a pneumatic pick and place system. In a
pneumatic pick and place system, vacuum suction may be fluidly
connected to a pick and place head for controlling the lift and
placement of the part. A pick and place head may include a vacuum
or gripper nozzle. One manner in which equipment used to pick the
component 50 out of the tray 1 and place the component 50 on a
suitable mounting surface (not shown) may operate is to sense the
top of the tray and/or the component when performing a placement
operation. The tray for component packaging 1 helps to accomplish
this by providing a spacer tray that is flush with or slightly
above the component. A pneumatic pick and place system may include
a motion envelope and a cycle time to lift and place the part.
Preferably, cycle time is minimized to improve the efficiency of
the pick and place system and reduce costs. The tray for component
packaging 1 helps to accomplish this by providing a multi-piece
tray having a spacer tray 30 that can be removed to reduce/minimize
the lift travel required to remove the part from the packaging tray
1.
[0066] In addition, some applications preferred that the same pick
and place system can be used to a variety of components. For
example, it may be desirable that the same piece of pick and place
equipment is suitable for use with components, such as electrical
connectors, having varying heights. The tray having a spacer tray
that may be removed from a base tray prior to the removal of the
component helps achieve improved placement rates of components
having different heights.
[0067] A tray feeder or loader system 80 may be provided to
delivery trays to the pick and place system. For example, as shown
in FIG. 10 a magazine 81 may be provided having shelves 82 for
receiving and holding trays 1. Preferably, the trays 1 include a
feature for registration of the trays within the feeder system 80
and also within the pick and place system 70 to help ensure
accurate placement of trays and hence accurate picking of parts
from the tray. For example, the tray 1 may include at least one
cut-out or angled corner to help ensure proper orientation and
positioning of the tray 1 within the tray feeder system 80 and/or
pick and place system 70. The other corners of the tray may include
radius corners.
[0068] While systems and methods have been described and
illustrated with reference to specific embodiments, those skilled
in the art will recognize that modification and variations may be
made without departing from the principles described above and set
forth in the following claims. Accordingly, reference should be
made to the following claims as describing the scope of disclosed
embodiments.
* * * * *