Electrolytic apparatus with unequal legged basket-carrier

An electrolytic apparatus and a material handling apparatus, including a pair of drive chains oriented to rotate in a substantially vertical plane. One or more product carriers, each including a basket portion, are supported by the chains. As the chains rotate, the product carriers are translated along a path in a substantially vertical plane. One tier of treatment tanks, or two tiers of vertically separated treatment tanks, may be positioned below the drive chains. Workpieces, such as encapsulated electronic components, may be placed within the baskets and translated by the drive chains for sequential immersion in each tank. Sprocket arrays engaged with each drive chain at positions above each tank direct the baskets first upward and then downward over the tank end walls, or over any barriers between the tanks.

FIELD OF THE INVENTION 
This invention relates to apparatus for transporting materials along a path 
in a substantially vertical plane. More particularly, the invention 
relates to chain-driven apparatus for transporting materials along a path 
in a substantially vertical plane for successive treatment at two or more 
treatment stations. 
BACKGROUND OF THE INVENTION 
Numerous conventional processes require that materials be successively 
immersed in two or more tanks. Important examples of such processes 
include the electroplating and chemical treatment of electronic 
components, such as integrated circuit leadframes and similar components. 
In the electronic component industry, discrete or integrated components are 
typically encapsulated in an electrically insulating material such as a 
plastic or ceramic package. Metal contacts or leads generally protrude 
from the package. These contacts or leads often require electroplating or 
chemical treatment after encapsulation. 
It is conventional to accomplish such treatment by loading the parts onto 
racks or into baskets, and sequentially bathing such racks or baskets into 
tanks of cleansing and plating solution or the like. It is also 
conventional to convey the parts along a horizontal path through 
successive treatment stations using conveyor belts or rails. 
For example, U.S. Pat. No. 4,534,843, issued Aug. 13, 1985 to Johnson, et 
al., discloses an electroplating apparatus having a flexible, electrically 
conductive conveyor belt that runs in a horizontal loop. Suitable shaped 
electronic components may be gripped by members attached to the bottom 
edge of the belt and carried along a horizontal path through successive 
treatment tanks. Each treatment tank has notches (weirs) at each end, 
allowing the components to enter and exit the tank but also allowing fluid 
in the tank to drain out, triggering a need for a means for collecting and 
recycling the escaping fluid. A complicated loading mechanism is employed 
to position appropriately sized and oriented components so that they may 
be gripped by the gripping members. In order to adapt the apparatus to 
transport differently sized or shaped components, the gripping members 
must be removed from the belt and replaced by differently sized and shaped 
gripping members. During electroplating operations, electric current is 
supplied from a power source through the entire electrically conductive 
conveyor belt, to the components gripped by the gripping members. 
A similar conventional apparatus is disclosed in U.S. Pat. No. 4,508,611, 
issued Apr. 2, 1985 to Johnson, et al. The apparatus of U.S. Pat. No. 
4,506,611 has a vertically oriented, electrically conductive, conveyor 
belt whose flat surface is oriented horizontally. The belt edges have 
means by which components may be attached thereto by a loading mechanism. 
Otherwise, the apparatus of U.S. Pat. Nos. 4,506,611 and that of 4,534,811 
are similar. Both require that the treatment tanks be linearly arranged in 
the same horizontal plane, both require complicated loading mechanisms, 
and both are energy inefficient because they supply electric current that 
flows through the entire conveyor belt in order to supply electric current 
to the components engaged therewith. 
Conventional material handling systems, in general, embody all or some of 
the following disadvantages: complexity, in the sense that extremely 
accurate positioning mechanisms are required for loading and unloading the 
components to be conveyed thereby; inability to transport parts having a 
wide range of shapes and sizes without system modifications; bulky size, 
occupying large floor areas without realizing the floor space economies 
attainable by maximizing the use of vertical space above a given floor 
area; low production rate, because the products to be treated are oriented 
with their longitudinal axis parallel to their travel path so that few 
products are processed per unit length of the product travel path; 
unreliability, in the sense that a percentage of the products being 
transported, especially delicate products such as electronic components, 
are damaged during the loading and unloading processes or lost during 
transportation along the process path; inefficient electric power usage, 
due to failure to limit the supply of electric power to the process areas 
only. 
Until the present invention, it was not known how to transport materials 
for treatment at successive treatment stations in a manner eliminating all 
the mentioned disadvantages. 
SUMMARY OF THE INVENTION 
The inventive material handling apparatus includes a pair of drive chains 
(each configured as a continuous loop oriented in a substantially vertical 
plane), and one or more rigid members attached to the pair of drive 
chains. A product carrier having a basket portion is attached to each 
rigid member, and a product (such as an integrated circuit leadframe) is 
placed in each carrier basket portion. The basket portions are preferably 
shaped and dimensioned so that products of various types, shapes, and 
sizes may be placed therein. A power source rotates the drive chains so as 
to translate each member, carrier, and product along a path in a 
substantially vertical plane. One or more treatment tanks may be 
positioned beneath the drive chains. Sprocket arrays are positioned so as 
to engage with each drive chain above a wall of each tank, so as to direct 
each member, carrier, and product upward over the tank wall and then 
downward into treating fluid contained in the tank. 
In one embodiment, the tanks are all positioned at substantially the same 
vertical level. In a preferred embodiment, one tier of tanks is positioned 
above (or below) a second tier of tanks, so that the drive chains 
translate the products first generally horizontally through the first tier 
of tanks, then upward (or downward) to a different vertical level, and 
then generally horizontally through the second tier of tanks. 
In order to electroplate the products, or portions thereof (such as 
integrated circuit leadframes), each carrier has an electrically 
conductive portion on which the product may rest. An electric power source 
provides current that flows to the product through the carrier only at 
desired time intervals such as when a product (or the appropriate portion 
thereof) is immersed in the appropriate tank. The inventive apparatus 
preferably includes insulating portions that prevents the flow of 
electroplating current except through a compact portion of the apparatus 
between the electric power source and the immersed product. 
In a preferred embodiment, the rigid member driven by the drive chains 
comprises two L-shaped portions, each attached to one of the drive chains, 
and a product carrier attached between the L-shaped portions. The product 
carrier is stamped from a flat metal sheet and bent into a basket shape. 
In an alternative embodiment, the rigid member is an L-shaped bar, having a 
vertical bar portion attached to one drive chain and a horizontal bar 
portion attached to the other drive chain. The product carrier comprises a 
vertical rod attached to the horizontal bar portion and a basket portion 
suspended from the vertical rod. In this embodiment, the L-shaped bar 
kinematically prevents the carriers from swinging. In variations on this 
embodiment, the rigid member is a horizontally oriented straight bar (or 
rod).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
A preferred embodiment of the invention will be described with reference to 
FIGS. 1 and 2. FIG. 1 is a simplified perspective view of this embodiment. 
Drive chains 1 and 2 are each oriented in a substantially vertical plane. 
Each is driven in a substantially vertical path by drive sprockets 8, 
which may be powered by a conventional power source (not illustrated), and 
which are dimensioned to engage the links of chains 1 and 2. Product 
carrier 700 is attached between chains 1 and 2. Part 6, which may be an 
encapsulated electronic component, rests in basket portion 703 of carrier 
700. Any number of additional product carriers identical to carrier 700 
may be attached between chains 1 and 2, each for supporting a part (such 
as an encapsulated electronic component) identical to or different from 
part 6. Carriers 20-26 are simplified representations of seven such 
additional carriers. Part 27 rests in carrier 23, and part 28 rests in 
carrier 24. 
Central portion 703 of product carrier 700 (shown in greater detail in FIG. 
2) is preferably stamped from a flat sheet of metal and then bent into a 
basket shape. L-shaped rods 701 and 702 suspend portion 703 from drive 
chains 1 and 2. Chains 1 and 2 may be spaced vertically (as shown) or 
alternatively may be positioned at the same vertical level. Because chains 
1 and 2 are spaced vertically in FIG. 1, the vertical portions of rods 701 
and 702 have unequal length so as to suspend portion 703 generally 
horizontally. 
As the drivers (drive sprockets 8) rotate chains 1 and 2 at the same 
rotational speed, each of carriers 700 and carriers 20 through 26 is 
translated along a path in a substantially vertical plane. Part 6 will 
initially translate parallel to the direction of arrows 16 and later will 
translate parallel to the direction of arrows 18, as drive sprockets 8 
rotate counterclockwise. 
Treatment tanks 10, 12, and 14, containing fluids 10a, 12a and 14a, 
respectively, are separated by walls such as wall 11d positioned below 
drive chains 1 and 2. When the basket portion containing part 27 
approaches a wall (such as wall 11a), it is directed first upward over the 
wall and then downward so as to be at least partially immersed in the 
fluid (for example, fluid 12a) in the next tank (for example, tank -2), 
provided there is a fluid containing tank in the proper position. When the 
basket approaches end wall 11b, it is directed upward over the end wall 
and then downward outside the tank bounded by the end wall. 
A pair of sprocket arrays 7 (one sprocket array 7 for each drive chain) 
above wall 11a direct the drive chains first upward and then downward, as 
they rotate, to direct the carrier assemblies translating past arrays 7 
(such as carrier 24 supporting part 28) over wall 11a. The last pair of 
sprocket arrays 9 disposed above end wall 11b serves a similar function as 
does the first pair of arrays 7. 
Drive sprockets 8 are held above floor 29 by support means 70. Tanks 10, 12 
and 14 are supported above floor 29 by support means 74. Stabilizing 
chains 37 (to be discussed below with reference to FIG. 2) are supported 
by conventional means (not shown) above floor 29. Pinned wheel 40 (to be 
discussed below with reference to FIG. 2) is supported above floor 29 by 
support means 73. The sprockets comprising sprocket arrays 7, 9, and other 
similar sprocket arrays disposed therebetween (but not shown in FIG. 1) 
are similarly supported above floor 29 by support means (not shown in FIG. 
1). 
FIG. 2 is a more detailed view of a portion of the apparatus of FIG. 1. 
Stabilizing sprockets 34 and 35 of FIG. 2, rotatably attached between 
horizontal sections 705 and 706 of L-shaped members 702 and 701 
respectively, are guided by stabilizing chains 37. Each outer horizontal 
portion 706 is electrically insulating, and each inner horizontal portion 
705 is electrically conducting. Each stabilizing chain 37 serves to 
stabilize basket portion 703. At least the lower one of chains 37 permits 
electric current to flow from bus bar 47, through chain 37, inner portion 
of member 702 (but not outer horizontal portion 706 of member 702), and 
conductive portion of basket 703, to a part (not shown in FIG. 2), such as 
part 6 of FIG. 1, resting in basket 703. In variations on the embodiment 
shown in FIG. 2, the upper one of chains 37, or both of chains 37, may be 
connected to bus bar 47 (or to one or more similar bus bars), for 
supplying current to the conductive portion of basket 703 and any part 
resting therein. Provision of electrical current to a part resting in 
basket 703 is desirable, for example, to permit the part to be 
electroplated in a tank containing an appropriate solution. The necessary 
electric power for electroplating is supplied by power source 45 through 
cable 46 to the appropriate one or both of chains 37. In an electroplating 
operation, one pole of source 45 is connected to cable 46 to cause bus bar 
47, one or both of chains 37, and basket 703 to serve as a cathode, and 
the other pole of source 45 is connected to an anode (not shown) immersed 
in the electroplating solution. 
Preferably at least one of chains 37 has two or more insulating links such 
as links 39, bus bar 47 (on which said at least one chain 37 rests) is a 
nickel plated copper bus bar, cable 46 is in direct electrical contact 
with bus bar 47, and bus bar 47 is in direct electrical contact with the 
electrically conductive links (such as links 38) of each stabilizing chain 
37 resting thereon. This arrangement enhances the energy efficiency of the 
system by restricting electric current flow to that electrically 
conductive portion of each stabilizing chain 37 in contact with one or 
both of sprockets 34 and 35. If necessary to provide continuous electric 
contact as the parts move through a number of electroplating tanks, 
several bus bars of the same type as bus bar 47 are attached to electric 
cables, such as cable 46, in turn attached to electric power source 45 (or 
to a different electric power source). Each such bus bar is positioned in 
contact with one or both of chains 37 at a selected position (such as 
above an electroplating tank) so that current is drawn from the power 
source, through the electric cables to the bus bars only at desired time 
intervals, such as when part 6 is immersed in an appropriate 
electroplating treatment tank. 
FIG. 3 is a simplified perspective view of an alternative embodiment of the 
invention. Drive chains 51 and 52, sprocket arrays 57 and 59, and tanks 
60, 62 and 64 correspond respectively to chains 1 and 2, sprocket arrays 7 
and 9, and tanks 10, 12 and 14 in the FIG. 1 embodiment. Member 53, rod 
54, and basket 55 are an alternative embodiment of product carrier 700 of 
the FIG. 1 embodiment. Chains 51 and 52 are positioned at substantially 
the same vertical level, and member 53 is a horizontally oriented straight 
bar (or rod) for suspending basket 55 below chains 51 and 52. In contrast, 
chains 1 and 2 are vertically spaced in the FIG. 1 embodiment. 
The material handling systems of FIGS. 1 and 3 operate identically, except 
that in the FIG. 1 embodiment the L-shape of portions 701 and 702 
kinematically prevents basket 703 from excessive swinging motion, while in 
the FIG. 3 embodiment, the rotational freedom of bar 53 relative to chains 
51 and 52 permits rod 54 and basket 55 to swing, except as such swinging 
is limited by gravitational and frictional forces. 
FIG. 4 is a portion of another alternative embodiment of the system of the 
invention, in which the basket portion of the product carrier positioned 
outside drive chains 1 and 2 (rather than between the drive chains). 
Basket 5' and electrically conducting member 4' are pivotally attached to 
L-shaped member 3' by hinge 31'. Member 3' includes L-shaped, electrically 
insulating portion 30' and horizontal, electrically conducting portion 
32'. Portion 4' may rotate or pivot about hinge 31' so that portion 4' 
(and basket 5' rigidly attached thereto) may have a variety of 
orientations, including vertical and horizontal orientations. Sprockets 34 
and 35 are rotatably attached to portion 32' as in the FIG. 2 embodiment. 
Sprockets 34 and 35 are guided by stabilizing chains 37, one or both of 
which may rest on a bus bar such as bus bar 47. Basket 5' may be rotated 
about hinge 31' upward out of an electroplating tank for easy replacement 
of an anode in the tank. 
All other components of the FIG. 1 system, including sprockets 7 and 9, are 
included in the FIG. 4 embodiment but are not shown in FIG. 4. 
FIG. 5 is a simplified side elevational view of another preferred 
embodiment of the invention. The FIG. 5 apparatus is a two-tiered 
variation on the FIG. 1 apparatus, and includes one or more L-shaped 
support members (similar to member 3 shown in FIG. 9) attached between 
drive chains 101 and 102. Each support member includes a vertical rod 
portion 129. Drive chain 101 is driven by drive sprockets 108. Drive chain 
102 is driven by drive sprockets 109. Sprockets 109 and chain 102 are 
disposed above the plane of FIG. 5, and if the plane of FIG. 5 represents 
the plane midway between chains 101 and 102, then sprockets 108 are 
disposed below the plane of FIG. 5. Thus, rods 129 are drawn so as to 
indicate that rods 129 hang in a vertical plane behind the plane of (i.e., 
into the page with respect to) chain 102 and sprocket 109. 
A lower tier of tanks 200, 201, 210 and 211 is supported above floor 239 by 
support members 253. An upper tier of tanks, including tanks 212, 213, 222 
and 223 is supported above tanks 200, 201, 210 and 211 by taller support 
members 252. Support members 252 and 253 are positioned away from the path 
of baskets 130 and rods 129, so as not to obstruct translation of these 
baskets and rods. Any number of tanks may be included in the lower tier 
and any number may be included in the upper tier. Tanks 200, 201, 210, 
211, 212, 213, 222 and 223 contain fluids 240, 241, 242, 243, 244, 245, 
246 and 247 respectively. Barrier 230 separates tanks 200 and 201, barrier 
231 separates tanks 210 and 211, barrier 233 separates tanks 212 and 213, 
and barrier 234 separates tanks 222 and 223. End walls 229 define the ends 
of each tier of tanks. 
As drive chains 101 and 102 rotate counterclockwise at the same rotational 
speed, baskets 130 (each of which hangs below a rod 129) pass sequentially 
through tanks 200-223. Parts (such as electronic components) may be placed 
into baskets 130 at loading station 252 prior to treatment in the tanks, 
and then removed from baskets 130 at unloading station 251 after treatment 
in the tanks. Stations 251 and 252 may be located at any desired location 
relative to the tanks. 
Sprocket arrays 111, 113, 115, 117, 119, 121, 123 and 125 are engaged with 
chain 102. Sprocket arrays 110, 112, 114, 116, 118, 120, 122 and 124 are 
engaged with chain 101. Thus, the sprocket arrays engaged With chain 102 
lie in the vertical plane of chain 102 (above the plane midway between the 
chains 101 and 102) and the sprocket arrays engaged with chain 101 lie in 
a vertical plane beneath the plane of the sprocket arrays engaged with 
chain 102. Sprocket arrays 110, 112, 114 and 116 lie directly beneath (and 
are obscured by) sprocket arrays 125, 123, 121 and 119 respectively. 
Similarly, the portion of chain 101 spanned by arrays 110 and 116 lies 
directly beneath (and is obscured by) the portion of chain 102 spanned by 
arrays 119 and 125. 
As in the FIG. 1 embodiment, sprocket arrays 110 and 111 direct drive 
chains 101 and 102 upward and then downward, thus directing basket 130, as 
it passes below arrays 110 and 111, so as to clear end wall 229 of tank 
200. Similarly arrays 112 and 113 direct the basket therebelow first 
upward and then downward, so as to avoid barrier 230 which separates tanks 
200 and 201. Also in the same manner, arrays 120 and 121 direct the basket 
therebelow upward and then downward to avoid barrier 233. 
Arrows 250 indicate the path ("path 250") along which each basket 130 
translates as chains 101 and 102 rotate. Path 250 lies in a substantially 
vertical plane. 
The configuration of the FIG. 5 embodiment is particularly advantageous 
because it minimizes the area of floor 240 occupied by the apparatus for a 
given number of treatment tanks. In contrast, the FIG. 1 embodiment would 
occupy more floor space to accommodate all of tanks 200-223, since the 
tanks would all be positioned end-to-end along a horizontal line on the 
floor in the FIG. 1 embodiment. 
FIGS. 6, 7, and 8A-8C are enlarged views of baskets (which are also 
referred to herein as "basket portions" of "product carriers") suitable 
for use as part of any of the FIG. 1, the FIG. 3, the FIG. 4, or the FIG. 
5 embodiments of the inventive apparatus. 
Basket 300 of FIG. 6 is attached at the end of rod 301. The other end of 
rod 301 is attached to a rigid member (such as member 54 of FIG. 3) driven 
by the drive chain pair of the invention. Basket 300 is made of metal 
wire, and includes wire rod 302, end pieces 303 and central pieces 304. 
Pieces 303 and 304 are desirably spaced from each other to permit easy 
insertion and removal of workpieces (such as electronic components) in the 
basket. FIG. 8a is a cross-sectional view of piece 304 taken in a plane 
perpendicular to the axis of rod 302. For some applications, it is 
desirable that basket 300 be given an electrically insulating coating. For 
electroplating applications, it is preferable that upper portions 303b and 
304b of pieces 303 and 304, respectively, be given an electrically 
insulating coating but that lower portions 303a and 304a be left uncoated. 
The exposed metal surfaces of portions 303a and 304a will then provide 
electrical contact between rod 301 (attached directly to rod 302) and a 
component resting (in basket 300) against portion 303a or 304a or both 
portions 303a and 304a. 
In embodiments of the type shown in FIG. 1 or FIG. 4, a support member 
would be attached to either one or both of the end pieces 303 and 304 of 
basket, 300, in place of rod 301 (shown attached to the central portion of 
basket 300 in FIG. 6). 
FIG. 7 is an alternative embodiment of an end piece of the basket of FIG. 
6. For electroplating applications, lower portion 311a consists of bare 
metal wire, while upper portion 311b is preferably given an electrically 
insulating coating. FIGS. 8b and 8c are cross-sectional views of end and 
central pieces that are substitutable for the end and central pieces of 
basket 300. For electroplating applications, lower portion 500a of the 
FIG. 8b unit, and lower portion 600a of the FIG. 8c unit are bare metal 
wire, while upper portions 500b and 600b are wire having an electrically 
insulating coating. 
FIG. 9 is an alternative embodiment of a product carrier suitable for use 
as a substitute for the carriers of the embodiment described with 
reference to FIGS. 1 and 2. The FIG. 9 carrier includes an L-shaped rigid 
member 3 supported between chains 1 and 2. Carrier rod 4 extends downward 
from central portion 32 of rigid member 3 to support basket 5. Member 3 
includes electrically insulating outer portions 30 and 31, and 
electrically conductive central portion 32 attached to rod 4, for example 
by a weld. Portions 30 and 31 may be formed of plastic, and portion 32 and 
rod 4 may be composed of stainless steel or another metal. Portions 30 and 
31 are rotatably attached to chains 1 and 2, respectively, such as by pin 
units 36. Rod 4 is attached to electrically conductive wire rod 44 (a 
component of basket 5), for example by a weld. 
In a similar manner to the FIG. 2 embodiment, sprockets 34 and 35 are 
rotatably attached to central portion 32, and stabilizing chains 37 are 
provided for guiding stabilizing sprockets 34 and 35. Each stabilizing 
chain 37 serves to stabilize basket 5, and at least one of chains 37 
permits electric current to flow from bus bar 47, through said at least 
one of chains 37, central portion 32, rod 4, and the conductive portion of 
basket 5, to part 6 resting in basket 5. The necessary electric power for 
electroplating operations is supplied by power source 45 through cable 46 
to at least one of chains 37. 
Wheel 40 (or a similar spacing mechanism) having teeth (or pins) may be 
positioned so that the teeth (or pins) will engage with the rods (for 
example rod 4), to ensure even spacing of baskets 5, and to ensure that 
the parts being treated (for example part 6) will be positively placed in 
or removed from the baskets when desired. 
Various modifications and alterations in the structure and method of 
operation of this invention will be apparent to those skilled in the art 
without departing from the scope and spirit of this invention. Although 
the invention has been described in connection with specific preferred 
embodiments, it should be understood that the invention as claimed should 
not be unduly limited to such specific embodiments.