Abstract:
A bonding device for bonding a flexible printed circuit board (PCB) to a printhead assembly includes an enclosed work area; a first heater assembly provided within the enclosed work area and movable along a first path; a bending mechanism provided within the enclosed work area and adapted to bend the bonded PCB; a second heater assembly provided within the enclosed work area and movable along a second path; a nest structure for receiving the printhead assembly, the nest structure movable along a third path; and a control system to control operation of the heater assemblies, bending mechanism, and nest structure. The first path and the second path are constrained to an area within the enclosed work area, and the third path crosses a boundary of the enclosed work area.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 13193734 filed Aug. 19, 2008, all of which is herein incorporated by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention generally relates to bonding a flexible printed circuit board (PCB) to integrated circuits, such as that of a printhead. 
       CO-PENDING APPLICATIONS 
       [0003]    The following applications have been filed by the Applicant with the present application: 
         [0000]                                                12/193,715   12/193,716   7,880,900   7,924,440   7,863,890       7,804,292   7,786,723   7,866,784   12/193,724   7,971,472       7,789,477   7,987,699   8,006,967   7,984,640   7,721,420       7,845,068   12/193,732   7,967,046   7,877,875   12/193,736       12/193,743   12/193,745   12/193,739   12/193,748   12/193,741       7,805,832   7,979,979   12/193,750   7,877,876   12/193,751                    
The disclosures of these co-pending applications are incorporated herein by reference.
 
       CROSS REFERENCES 
       [0004]    The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference. 
         [0000]    
       
         
               
               
               
               
               
             
           
               
                   
               
             
             
               
                 7,744,195 
                 7,645,026 
                 7,322,681 
                 7,708,387 
                 7,753,496 
               
               
                 7,712,884 
                 7,510,267 
                 7,465,041 
                 7,857,428 
                 7,465,032 
               
               
                 7,401,890 
                 7,401,910 
                 7,470,010 
                 7,735,971 
                 7,431,432 
               
               
                 7,465,037 
                 7,445,317 
                 7,549,735 
                 7,597,425 
                 7,661,800 
               
               
                 7,712,869 
                 7,712,876 
                 7,712,859 
                 7,794,061 
                 7,845,765 
               
               
                 7,798,603 
                 7,784,902 
                 7,775,630 
                 7,824,010 
                 7,841,695 
               
               
                 7,841,697 
                 7,922,313 
                 8,011,773 
                 7,597,431 
                 7,887,160 
               
               
                 12/140,265 
                 12/183,003 
                 11/688,863 
                 7,837,297 
                 7,475,976 
               
               
                 7,364,265 
                 11/688,867 
                 7,758,177 
                 7,780,278 
                 11/688,871 
               
               
                 7,819,507 
                 7,654,640 
                 7,721,441 
                 12/014,767 
                 12/014,768 
               
               
                 12/014,769 
                 7,832,838 
                 7,862,162 
                 7,758,149 
                 12/014,773 
               
               
                 7,758,152 
                 12/014,775 
                 7,753,477 
                 12/014,777 
                 12/014,778 
               
               
                 12/014,779 
                 12/014,780 
                 7,891,763 
                 7,815,282 
                 12/014,783 
               
               
                 7,832,834 
                 12/014,785 
                 12/014,787 
                 7,753,478 
                 12/014,789 
               
               
                 7,845,778 
                 12/014,791 
                 7,771,002 
                 12/014,793 
                 7,766,451 
               
               
                 7,771,007 
                 7,819,500 
                 12/014,801 
                 12/014,803 
                 7,857,438 
               
               
                 12/014,805 
                 12/014,806 
                 12/014,807 
                 12/049,371 
                 7,845,755 
               
               
                 7,727,348 
                 7,845,763 
                 7,771,034 
                 7,922,279 
               
               
                   
               
             
          
         
       
     
       BACKGROUND 
       [0005]    Pagewidth printers that incorporate micro-electromechanical components generally have printhead integrated circuits that include a silicon substrate with a large number of densely arranged micro-electromechanical nozzle arrangements. Each nozzle arrangement is responsible for ejecting a stream of ink drops. 
         [0006]    In order for such printers to print accurately and maintain quality, it is important that the printhead integrated circuits be tested. This is particularly important during the design and development of such integrated circuits. 
         [0007]    In order to test such integrated circuits, it is necessary to attach some form of data communication arrangement to the integrated circuits. Flexible printed circuit boards are an example of such a data communication arrangement and have been used to communicate data to integrated circuits. 
       SUMMARY OF THE INVENTION 
       [0008]    According to an aspect of the present disclosure, a bonding device for bonding a flexible printed circuit board (PCB) to a printhead assembly comprises an enclosed work area; a first heater assembly provided within the enclosed work area and movable along a first path; a bending mechanism provided within the enclosed work area and adapted to bend the bonded PCB; a second heater assembly provided within the enclosed work area and movable along a second path; a nest structure for receiving the printhead assembly, the nest structure movable along a third path; and a control system to control operation of the heater assemblies, bending mechanism, and nest structure. The first path and the second path are constrained to an area within the enclosed work area, and the third path crosses a boundary of the enclosed work area. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: 
           [0010]      FIG. 1  is a perspective view of a flexible printed circuit board (PCB) and a printhead assembly to be bonded, fastened or connected together according to a method of the invention with an apparatus of the invention; 
           [0011]      FIG. 2  is a perspective view of a bonding device for bonding together the flexible PCB and printhead assembly shown in  FIG. 1 , according to one embodiment of the present invention; 
           [0012]      FIG. 3  is a perspective view showing the internal bonding parts of the bonding device of  FIG. 2 ; 
           [0013]      FIG. 4  is a perspective view of a carriage of the bonding device of  FIG. 2  which is configured to carry a carrier on which the printhead assembly is supported for testing purposes; 
           [0014]      FIG. 5  is a perspective view of a vertical heated platen assembly of the bonding device of  FIG. 2 ; 
           [0015]      FIG. 6  is a perspective view of a horizontal heated platen assembly of the bonding device of  FIG. 2 ; 
           [0016]      FIG. 7  is a functional block diagram of the bonding device of  FIG. 2 ; 
           [0017]      FIG. 8  is a flowchart showing the steps involved with bonding together the flexible PCB and printhead assembly using the bonding device of  FIG. 2 ; 
           [0018]      FIGS. 9A-J  are schematic side views showing the relative positions of the internal bonding parts of  FIG. 3  when bonding the flexible PCB to the printhead assembly. 
           [0019]      FIG. 10  is a power and safety circuit of the bonding device of  FIG. 2 . 
           [0020]      FIG. 11  is a PLC circuit of the bonding device of  FIG. 2 . 
           [0021]      FIG. 12  is a heater circuit of the bonding device of  FIG. 2 . 
           [0022]      FIG. 13  is an air cylinder actuator circuit of the bonding device of  FIG. 2 . 
           [0023]      FIG. 14  is a pneumatic circuit of the bonding device of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0024]    According to an embodiment of the present invention, there is provided a bonding, attachment or fastening device or apparatus  10  shown in  FIG. 2  which is configured to bond a flexible printed circuit board (PCB)  12  to a printhead assembly  14  as shown in  FIG. 1 . The printhead assembly  14  has a carrier  16 . A lamination film is arranged on the carrier  16 . An ink ejection printhead  18  is carried on the film. 
         [0025]    The film defines a plurality of openings (not shown) which correspond with openings in the printhead  18  and in part of the carrier  16  so that the printhead  18  can be fed with fluid for testing purposes. 
         [0026]    The underside of the PCB  12  is coated with an adhesive and the carrier  16  is formed from liquid crystal polymer (LCP) material which is inherently resistant to heat deformation. In use, one or more bonding assemblies, fasteners or connectors or platen assemblies of the bonding device  10  mechanically bond the flexible PCB  12  to the printhead assembly  14  with the adhesive. A detailed description of the bonding device  10  is provided below. 
         [0027]    Turning to  FIG. 2 , the bonding device  10  has a housing or support structure assembly that includes a cabinet  20 . The cabinet  20  defines an internal space  22  and a front access opening to facilitate operator access to movable bonding parts  21  located in the internal space  22 . A light curtain generator is configured to generate a light curtain across the front access opening. The light curtain generator includes an elongate light transmitter  24  mounted to the cabinet on one side of the opening and an elongate light receiver  26  mounted to the cabinet  20  on the other side of the opening. In use, the transmitter  24  transmits a plurality of beams of light which are received by the receiver  26 , thereby forming the light curtain. 
         [0028]    The bonding device  10  further includes a control system or controller which is configured to cease the operation of the movable bonding parts  21 , including the bonding or heater assemblies, responsive to a breach of the light curtain. That is, any movement and heating of the parts  21  is immediately ceased in the event that the operator reaches a hand into the internal space  22 , thereby reducing the possibility of injury to the operator. 
         [0029]    The cabinet  20  includes an operator control panel  28  located at its base. The control panel  28  includes a row of control press-buttons  30  (i.e. actuators) configured to control the operation of the bonding device  10 . The outer press buttons  30   a ,  30   e  are START buttons which must be concurrently pressed before the PCB  12  can be bonded to the printhead assembly  14 . The controller is configured to control the heater assemblies to bond the PCB  12  to the printhead assembly  14  responsive to the buttons  30   a ,  30   e  being concurrently pressed. The START buttons  30   a ,  30   e  are spaced apart so that the operator cannot concurrently press both of them using a single hand. In this manner, the operator must have both hands located external to the cabinet  20  when initiating operation of the bonding device  10 , thereby ensuring that one hand cannot be located within the cabinet  20 . 
         [0030]    The bonding device  10  further includes an authentication system for authenticating the printhead assembly  14 . The authentication system includes an optical barcode scanner  15  configured to scan barcodes borne by either the printhead  18  or the printhead carrier  16 . The scanner  15  is fastened to the cabinet  20 , either in the space  22  or on a front panel, and reading of the barcodes is initiated when the operator presses a SCAN press button  30   b  of the operator control panel  28 . The controller is configured to control the heater assemblies to bond the PCB  12  to the printhead assembly  14 , only subsequent to the authentication of the printhead assembly  14 . 
         [0031]    The operator control panel  28  further includes an EMERGENCY STOP button  30   c  which can be pressed by the operator to cease operation of the bonding device  10  at any time and, in particular, in the event of an emergency. Pressing the EMERGENCY STOP button  30   c  causes the controller to cease any movement and heating of the heater assemblies. Once the emergency has been addressed, a RESET button  30   d  of the operator control panel  28  can be pressed to cause the controller to reset the operation of the bonding device  10 . 
         [0032]    The cabinet  20  also has an upper operator display panel  32 . The display panel  32  includes a “touch screen” liquid crystal display (LCD)  34  displaying information relating to the operation of the bonding device  10 . The operator can modify operating parameters of the bonding device  10  with a finger, by selecting various options displayed on the LCD  34 . The operator display panel  32  further includes a quartet of binary coded decimal (BCD) displays  36  for each displaying the set clamping pressure of a respective clamp or heater assembly of the bonding device  10 . A quartet of adjustment knobs  38  are provided on the roof of the cabinet  20  in register with respective BCD displays  36 . The set clamping pressure of the internal clamps and heater assemblies can be adjusted by adjusting corresponding adjustment knobs  38 . 
         [0033]    The bonding device  10  further includes a visible indicator in the form of a light emitting indicator such as a stack of three beacons  40  mounted to the roof of the cabinet  20 . The uppermost beacon includes a green light, the intermediate beacon includes an amber light and the bottommost beacon includes a red light. The beacons can be illuminated in a plurality of different ways to represent corresponding operational conditions of the bonding device, the operational conditions including: an occurrence of an operational error with the bonding device  10 ; a warm up period when the heater assemblies are being warmed up to a threshold operational temperature; a standby mode where the bonding device  10  is ready to initiate operation; and an operational mode where the bonding device  10  is operating. 
         [0034]      FIG. 3  shows the movable bonding parts  21  of the bonding device  10  which are located within the internal space  22  of the cabinet  20 . The movable bonding parts  21  include pneumatic actuators which are selectively actuated responsive to control signals from the bonding device controller. A detailed description of the bonding parts  21  is provided below. 
         [0035]    The movable bonding parts  21  include a pneumatic carriage  42  which is movably mounted within the cabinet  20  and is configured to carry the printhead assembly  14 . The carriage  42  defines a raised nest  44  in which the printhead assembly  14  can be nested. In use, the nest  44  carrying the printhead assembly  14  and PCB  12  can be rectilinearly moved from outside the cabinet  20 , to within the space  22  of the cabinet  20  via the front opening (before the light curtain  46  is generated) so that various bonding parts  21  can perform suitable operations to fasten the printhead assembly  14  and PCB  12  together. 
         [0036]      FIG. 4  shows the carriage  42  and the nest  44  in detail. The nest  44  defines an upwardly facing recess in which the printhead assembly  14  can be rested. A pair of locating pegs  48   a, b  extend upwardly from the base of the nest  44  and are spaced apart to correspond to complementary guide holes  50   a, b  defined in the printhead assembly  14  (see  FIG. 1 ). In use, the operator places the printhead assembly  14  in the nest  44  so that the locating pegs  48   a, b  extend through the guide holes  50   a, b.    
         [0037]    Furthermore, a pair of locating pins  56   a,b  extend upwardly from the base of the nest  44  and are spaced apart to correspond to: complementary guide holes  52   a,b  defined in the printhead assembly  14 ; and complementary guide holes  54   a,b  defined in the PCB  12  (see  FIG. 1 ). In use, the operator places the printhead assembly  14  in the nest  44  so that the locating pins  56   a, b  extend through the guide holes  52   a, b . In turn, the operator places the PCB  12  on the printhead assembly  14 , with the adhesive on its underside, so that the locating pins  56   a, b  extend through the guide holes  54   a, b . The bonding device  10  can then bond the PCB  12  and printhead assembly  14  together. 
         [0038]    Returning to  FIG. 3 , the movable bonding parts  21  further include a pneumatically driven vertical heated platen assembly  58 , a vertical clamping assembly  60 , a vertical forming bar assembly  62  and a horizontal heated platen assembly  64 . 
         [0039]    The vertical clamping assembly  60  and forming bar assembly  62  are of like construction. The vertical clamping assembly  60  includes a pneumatic actuator  65  which is fixed within the cabinet  20 , and a movable clamp  66  which is constrained to reciprocate rectilinearly upon actuation of the actuator  65 . Similarly, the forming bar assembly  62  includes a pneumatic actuator  68  which is fixed within the cabinet  20 , and a movable bar  70  (or member) which is constrained to reciprocate rectilinearly upon actuation of the actuator  68 . In use, the forming bar assembly  62  forms a bending mechanism for bending the flexible PCB  12 . 
         [0040]      FIG. 5  shows the vertical heated platen assembly  58  in detail. The heated platen assembly  58  includes a pneumatic actuator  72  fixed within the cabinet  20 , and a heater assembly  74  which is constrained to reciprocate rectilinearly upon actuation of the actuator  72 . The heater assembly  74  can move along a vertical path to bond the flexible PCB  12  to the printhead  18  with adhesive on the underside of the PCB  12 . 
         [0041]    The heater assembly  74  includes a steel platen  76 , a thermal insulation sheet  78  mounted to the steel platen  76 , and a thermally conductive brass platen  80  mounted to the insulation sheet  78 . The brass platen  80  tapers to an apex at its base for engagement with the PCB  12 . The brass platen defines an internal chamber in which a replaceable heater cartridge  82  is located. 
         [0042]      FIG. 6  shows the horizontal heated platen assembly  64  in detail. The heated platen assembly  64  includes a pneumatic actuator  84  fixed within the cabinet  20 , and a heater assembly  86  which is constrained to reciprocate rectilinearly upon actuation of the actuator  84 . The heater assembly  86  can move along a substantially horizontal path to mechanically bond the flexible PCB  12  to the printhead carrier  16  with adhesive on the underside of the PCB  12 . 
         [0043]    The heater assembly  86  includes a steel platen  88 , a silicone sheet  89  mounted to the steel platen  88 , a thermal insulation sheet  90  mounted to the silicone sheet  89 , and a thermally conductive brass platen  92  mounted to the insulation sheet  90 . The brass platen  92  defines a substantially flat engagement surface. The brass platen  92  further defines an internal chamber in which a replaceable heater cartridge  94  is located. 
         [0044]      FIG. 7  shows a block diagram of the bonding device  10 . The bonding device  10  includes a central control system or controller  100  for controlling the operations of the bonding device  10 . The controller  100  includes one or more processors and electronic interface circuitry for interfacing with the peripheral components. 
         [0045]    The controller  100  controls the operation of the pneumatic movable bonding parts  21 , as described in detail below, and receives feedback from each of those parts. The controller  100  further receives inputs from the operator control panel  28  as previously described, and displays information using the operator display panel  32  and the beacon stack  40 . The controller  100  further controls a light curtain generator  102  to generate the light curtain  46  ( FIG. 3 ), and is configured to cease any movement of the movable bonding parts  21  responsive to a breach of the light curtain  46  as previously described. The controller  100  further controls the barcode scanner  15  of an authentication system  104  to authenticate the printhead assembly  14  as previously described. 
         [0046]    Software is typically provided on a media, such as a magnetic or optical disk or solid state memory, which contains computer readable instructions for execution by the controller  100  to thereby perform the automated steps of the proceeding method  110 . 
         [0047]    A method  110  for bonding the flexible PCB  12  to the printhead assembly  14  is now described in detail below with reference to  FIG. 8 . The method  110  includes manual setup steps which the operator can perform in parallel and automated bonding steps which can be sequentially performed by the bonding device  10 . 
         [0048]    At step  112 , the operator removes the printhead assembly  14  from a clean storage facility. 
         [0049]    At step  114 , the operator holds a printhead barcode borne by the printhead assembly  14  in register with the barcode scanner  15  of the authentication system  104 . The operator then presses the SCAN press button  30   b  of the operator control panel  28  to scan the printhead barcode. The controller  100  compares the identity of the scanned printhead barcode with a list of valid printhead barcodes stored in memory and authenticates the printhead assembly  14  upon detecting a match. 
         [0050]    At step  116 , the operator loads the authenticated printhead assembly  14  into the nest  44  of the carriage  42 . The carriage  42  is located external to the internal space  22  of the cabinet  20  as shown in  FIG. 3 . As previously described, the locating pegs  48   a,b  and locating pins  56   a,b  extending from the nest  44  ( FIG. 4 ) are inserted into respective guide holes  50   a,b  and guide holes  52   a,b  defined in the printhead assembly  14  ( FIG. 1 ). 
         [0051]    At step  118 , the operator manually removes the flexible PCB  12  from an anti-static storage cabinet. 
         [0052]    At step  120 , the operator holds a PCB barcode borne by the PCB  12  in register with the barcode scanner  15  of the authentication system  104 . The operator then presses the SCAN press button  30   b  of the operator control panel  28  to scan the PCB barcode. The controller  100  compares the identity of the scanned PCB barcode with a list of valid PCB barcodes stored in memory and authenticates the PCB  12  upon detecting a match. 
         [0053]    At step  122 , the operator peels a protective backing strip from the authentic PCB  12  to reveal an exposed adhesive on the underside of the PCB  12 . 
         [0054]    At step  124 , the operator loads the authentic PCB  12  onto the carriage  42  with the adhesive facing downwards toward the previously loaded printhead assembly  14 . As previously described, the locating pins  56   a, b  extending from the nest  44  ( FIG. 4 ) are inserted into respective guide holes  54   a, b  defined in the PCB  12  ( FIG. 1 ). 
         [0055]    At step  126 , the operator initiates bonding of the PCB  12  to the printhead assembly  14  with the bonding device  10 . The operator concurrently presses the START buttons  30   a ,  30   e  with respective hands and the controller  100  moves the nest into the internal space  22  of the cabinet  20  as shown in  FIG. 9A . Subsequently, the controller  100  controls the light curtain generator  102  to generate the light curtain  46  across the front opening of the cabinet  20  ( FIG. 3 ). 
         [0056]    The controller  100  controls the heater cartridge  82  at the tip of the vertical heater assembly  74  to be heated. As shown in  FIG. 9B , the controller  100  actuates the pneumatic actuator  72  of the vertical heated platen assembly  58  so that the heater assembly  74  and nest  44  compress the printhead assembly  14  and PCB  12 . The heater cartridge  82  is heated for a predetermined period to ensure that the PCB  12  is bonded to a substrate of the printhead  18  with the adhesive. As shown in  FIG. 9C , the controller  100  then actuates the pneumatic actuator  72  of the vertical heated platen assembly  58  so that the heater assembly  74  is withdrawn from the PCB  12 . 
         [0057]    At step  128  of  FIG. 8 , the controller  100  controls the carriage  42  to move the nest  44  in register with the movable clamp  66  of the vertical clamping assembly  60  as shown in  FIG. 9D . The controller  100  actuates the pneumatic actuator  65  of the vertical clamping assembly  60  so that the printhead assembly  14  and PCB  12  are compressed between the nest  44  and clamp  66  as shown in  FIG. 9E . 
         [0058]    At step  130  of  FIG. 8 , the controller  100  actuates the pneumatic actuator  68  of the forming bar assembly  62  so that the movable bar  70  moves vertically downward and folds (or bends) the PCB  12  downwardly as shown in  FIG. 9F . 
         [0059]    At step  132  of  FIG. 8 , the controller  100  controls the heater cartridge  94  at the tip of the horizontal heater assembly  86  to be heated. As shown in  FIG. 9G , the controller  100  actuates the pneumatic actuator  84  of the horizontal heated platen assembly  64  so that the heater assembly  86  presses the bent PCB  12  against the printhead carrier  16  of the printhead assembly  14 . The heater cartridge  94  is heated for a predetermined period to ensure that the PCB  12  is firmly bonded to the printhead carrier  16  with the adhesive. As shown in  FIG. 9H , the controller  100  then actuates the pneumatic actuator  84  of the horizontal heated platen assembly  64  so that the heater assembly  86  is withdrawn from the PCB  12 . 
         [0060]    At step  134  of  FIG. 8 , a horizontal clamp in the form of the brass platen  92  clamps against the PCB  12  to compress the bonded PCB  12  between the printhead carrier  16  and brass platen  92  until the adhesive is set. 
         [0061]    At step  136  of  FIG. 8 , the controller  100  actuates the pneumatic actuator  68  of the forming bar assembly  62  so that the movable bar  70  moves vertically upwards as shown in  FIG. 9I . Subsequently, the controller  100  actuates the pneumatic actuator  65  of the vertical clamping assembly  60  so that the clamp  66  moves vertically upwards as shown in  FIG. 9J  and thereby releases the bonded assembly from compression. 
         [0062]    At step  138  of  FIG. 8 , the controller  100  controls the light curtain generator  102  to disarm the light curtain  46  and moves the nest  44  out from the internal space  22  of the cabinet  20  to the position shown in  FIG. 3 . The controller  100  controls the beacon stack  40  to signal that the bonding process is complete and the operator can then freely remove the bonded assembly from the nest  44 . A manual visual inspection of the bonded assembly can then be performed by the operator. 
         [0063]      FIG. 10  shows a circuit diagram of a power and safety arrangement of the bonding device  10 . With reference to the previous drawings, unless otherwise indicated, like reference numerals refer to like parts. 
         [0064]    Broadly, a 24 Volt power supply is indicated at  140 . A 5 Volt power supply is indicated at  142 . The power supplies  140 ,  142  are connected to a fuse arrangement  144 . 
         [0065]    In this diagram, the light curtain emitter and receiver or light curtain is indicated at  146 . The light curtain  146  is connected to a light curtain safety relay  148  that acts to cut the 24 Volt power supply  140  with a switch  150 . 
         [0066]    A safety mute relay is indicated at  152 . The relay  152  is configured to receive a signal from a PLC (described below) to cut off the 24 Volt power supply  142  to the heating arrangement (described below) and to the various pneumatic actuators (also described below). 
         [0067]    The emergency stop buttons  30   c  are indicated at  154  in  FIG. 11 . The buttons  154  are connected to a further safety relay  156 . The relay  156  is connected to both the power supplies  140 ,  142  to cut power when actuated. The relay  156  is also connected to a safety valve  158  for the pneumatic system of the bonding device  10 . 
         [0068]      FIG. 11  shows a PLC  160  that forms part of the controller  100 . The PLC  160  is programmed to control operation of the various components to achieve the method steps described above. 
         [0069]    The PLC  160  communicates with solenoid valves (described with reference to  FIG. 13 ) to operate of the vertical platen and clamping assemblies  58 ,  60 , the vertical forming bar assembly  62  and the horizontal heated platen assembly  64  at  162 . 
         [0070]    At  164 , the PLC  160  communicates with solenoid valves to operate the horizontal bar  70 , the clamp  66  and the carriage  42 . 
         [0071]    At  166 , the PLC  160  communicates with the mute relay  152 , a start lamp  168 , a carriage in signal and a scan lamp  170 . 
         [0072]    At  172 , the PLC  160  communicates with the beacon stack  40 . 
         [0073]    The PLC  160  also communicates with solid state switches ( FIG. 13A and 13B ) at  163 . 1  and with pressure sensors at  163 . 2  for the necessary feedback control. 
         [0074]    The PLC  160  communicates with the optical barcode scanner  15  at  163 . 3  and with an Ethernet connection at  163 . 4 . 
         [0075]    At  165 , the PLC  160  communicates with start buttons  167 . 
         [0076]    At  169 , the PLC  160  communicates with a scan console  171  of the scanner  15 . 
         [0077]      FIG. 12  shows a temperature controller  174  that is configured to control the temperature generated by the heater assemblies  74 ,  86 . The replaceable heater cartridges are indicated at  176 . Switches  178  for the heater cartridges  176  are connected to the controller  174 . Thermocouples  180  are connected to the controller  174  and are positioned to sense the temperature of the cartridges  176 . 
         [0078]      FIGS. 13A and 13B  show circuit diagrams of the electrical components associated with the pneumatic system of the bonding device  10 . 
         [0079]    A circuit for the vertical heated platen assembly  58  includes an “up” solid state limit switch  182 . 1  and a “down” solid state limit switch. A solenoid valve  186 . 1  actuates the assembly  58 . 
         [0080]    A circuit for the vertical clamping assembly  60  includes an “up” solid state limit switch  182 . 2  and a “down” solid state limit switch  184 . 2 . A solenoid valve  186 . 2  actuates the assembly  60 . 
         [0081]    A circuit for the forming bar assembly  62  includes an “up” solid state limit switch  182 . 3  and a “down” solid state limit switch  184 . 3 . A solenoid valve  186 . 3  actuates the forming bar assembly  62 . 
         [0082]    A circuit for the horizontal heated platen assembly  64  includes a pair of limit switches  185 . A solenoid valve  186 . 4  actuates the platen assembly  64 . 
         [0083]    A circuit for the heater assembly  86  including the brass platen  92  includes a solenoid valve  186 . 5  to actuate the heater assembly  86 . 
         [0084]    A circuit for retracting the horizontal heated platen assembly  64  includes a pair of limit switches  184 . 5 . A solenoid valve  186 . 6  actuates the platen assembly  64 . 
         [0085]    A circuit for a carriage actuator includes a mid-limit switch  189 . 1 , an “in” limit switch  189 . 2  and an “out” limit switch  189 . 3 . A pair of solenoid valves  193  provides the necessary actuation. 
         [0086]    A circuit for the carriage  42  includes an “in” limit switch  191 . 1  and an “out” limit switch  191 . 2 . A solenoid valve  195  is provided for displacement of the carriage  42 . 
         [0087]    As described above, the switches and the solenoid valves are connected to the PLC  160  to facilitate control of the electrical components and thus the pneumatic circuit described below. 
         [0088]      FIG. 14  shows the pneumatic circuit or system referred to above. With reference to the previous drawings, like reference numerals refer to like parts, unless otherwise specified. 
         [0089]    The circuit receives a pressurized air supply via, in series, a pressure regulator  206 , a manual valve  208  and the safety valve  158 . 
         [0090]    The pressurized air supply is then delivered to via pressure regulators  216  to the various components described above. 
         [0091]    A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention. 
         [0092]    In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.