Abstract:
Provided is a cut tape/leaderless feeder finger for use in tape feeders for component mounters. The cut tape/leaderless feeder finger can be attached to existing component tape feeders to allow feeding of component tape without a leader. The cut tape/leaderless feeder finger includes a stripping mechanism that folds and creases the top cover of component carrier tape to expose the component in the tape. The cover tape stays attached to the carrier tape and is folder and creased out of the way of the feeder mechanism and the chip mounter. The component tape passes between guides that retain the component in the tape until it is picked by the component mounter.

Description:
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/786,620, filed Mar. 15, 2013, which is hereby incorporated by reference in its entirety. 
         [0002]    Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57. 
     
    
     FIELD OF THE DISCLOSURE 
       [0003]    The present disclosure relates generally to a tape feeder for use in chip mounters. 
       BACKGROUND 
       [0004]    In a conventional component tape feeding method the tape cover is removed by indexing a take-up reel along with indexing of the component supply tape, where the cover is detached and passed around a fixed guide surface and maintained under tension by the take-up reel. 
         [0005]    The majority of existing tape feeders utilize a sprocket having pins on the periphery thereof which are engagable in the indexing holes of the component tape so as to feed the tape by rotation of the sprocket. These prior art tape feeders require the component tape reel be supplied with a foot long leader attached to the end of the component reel for the purpose of starting the feed process. Tape feeders are generally stacked together side-by-side to provide the maximum amount of feeders in a minimum amount of space and generally it is necessary to remove a feeder in order to change the component tape. 
       SUMMARY OF THE DISCLOSURE 
       [0006]    The present disclosure relates generally to a tape feeder for use in chip mounters. In an embodiment, the tape feeder includes a component tape guide mechanism that delivers the tape to an indexing sprocket where the component is removed for subsequent handling, such as transfer to a conveyor or a circuit board. 
         [0007]    In an embodiment, the disclosure is directed to feeders using paper tapes having pockets containing surface mountable electrical components. Typically the top cover of the component tape is peeled away from the substrate so as to open each pocket in turn, and thus provide access to the component therein. Auxiliary covers or movable “shutters” often are provided to prevent loss of components from opened pockets. 
         [0008]    Several types of supply tapes are used presently, and the disclosure is applicable to these and other component supply tapes. One tape has a paper substrate embossed to define component holding pockets which are enclosed by a separable thin plastic top cover; another tape has holes all the way through a cardboard substrate with top and bottom covers for the holes so as to define the component pockets. 
         [0009]    Current systems that use supply tapes have several drawbacks. For example, loading the feeders is often time consuming and requires disposing of valuable components if a leader is not attached to the tape. Moreover, if a jam or breakage of the tape occurs with standard, current tape feeders, it is generally necessary to remove and replace the entire feeder assembly or to shut it down for an uneconomical length of time necessary to clear the jam or to rethread the tape in the feeder and/or the cover material into the peeler. 
         [0010]    In an embodiment, the present disclosure provides a cut tape/leaderless feeder finger for use in component tape feeders that redefines the concept of feeding component tape to a chip mounter, the cut tape/leaderless feeder finger includes a housing body, tape guide, and cover tape separator. In an embodiment, the cut tape/leaderless feeder finger can be mounted on existing component tape feeders of any manufacturer. Alternatively, the cut tape/leaderless feeder can be formed integrally or as part of a new tape feeder system. 
         [0011]    In an embodiment, the present disclosure also provides a cut tape/leaderless feeder finger for use on a component tape feeder having a guide structure for stable feeding of component tape to the indexing sprocket. The guide structure includes an opening through which the component can be accesses by the chip mounter. 
         [0012]    In an embodiment, the present disclosure also provides a cut tape/leaderless feeder finger for use on a component tape feeder having a guide structure with a fixed cover tape separator utilized to guide the top cover out of the way of the component tape opening while folding and creasing the cover onto the substrate for easy exit from the feeder body. In such an embodiment, the cover is only partially removed from the tape body, such that the cover does not need to be separately collected after use, but rather is collected after use with the rest of the tape body. This significantly simplifies the tape feeder process. 
         [0013]    According to an aspect of the present disclosure there is provided a cut tape/leaderless feeder finger used in conjunction with component tape feeders, the cut tape/leaderless feeder finger including: a frame along which the component tape is fed, a fixed cover tape separator, and a guide mechanism that pushes the component tape against the frame and into the exit opening. The empty substrate and folded top cover are guided out of the feeder finger and into the exit tunnel of the component feeder. The empty component tape with its top cover attached is discarded. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is an isometric view of an embodiment of the disclosure. 
           [0015]      FIG. 2  is a bottom plan view of the embodiment of  FIG. 1 . 
           [0016]      FIG. 3  is a left side view of the embodiment of  FIG. 1 . 
           [0017]      FIG. 4  is a right side view of the embodiment of  FIG. 1 . 
           [0018]      FIG. 5  is a rear view of the embodiment of  FIG. 1 , 
           [0019]      FIG. 6  is a rear view with tunnel shown in  FIG. 1   
           [0020]      FIG. 7  is a top view of the embodiment of  FIG. 1  illustrating the tape guide and top cover separator portions of the device. 
           [0021]      FIG. 8  is a detail view of the cover tape separator of  FIG. 1   
           [0022]      FIGS. 9 -10  are partial top views illustrating the tape feeding and cover peeling operations 
           [0023]      FIG. 11  is an isometric view of the bottom of  FIG. 1 . 
           [0024]      FIG. 12  is a partial isometric view illustrating a component supply tape with pocketed substrate, cover therefore, and component carried thereby. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    Although specific embodiments of the present disclosure will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present disclosure. Various changes and modifications obvious to one skilled in the art to which the present disclosure pertains are deemed to be within the spirit, scope and contemplation of the present disclosure as further defined in the claims. 
         [0026]    Embodiments of the present disclosure are intended to describe a system that connects to and operates with existing tape feeders systems. For example, in some embodiments, the system described herein operates in conjunction with the tape feeder described in U.S. Pat. Nos. 8,006,373 and 7,448,130, incorporated herein by reference. Of course, it is to be understood that the present disclosure can be used with any new or existing tape feeder systems. 
         [0027]    Referring to  FIG. 1 , illustrated is a perspective view of the present disclosure which includes a cut tape/leaderless feeder finger. The apparatus includes a feeder finger body ( 14 ), tape guide ( 15 ), and cover tape separator ( 12 ), such as, for example, a plow blade. Cover tape separator ( 12 ) is used for feeding a conventional carrier tape, for example, as illustrated in  FIG. 12 , with successive sprocket holes ( 33 ) and indexed pockets ( 31 ) for carrying small components and used in conjunction with various component feeders for surface-mounting of the small components onto a printed circuit board (PCB). 
         [0028]    Referring to  FIG. 2 , illustrated is the bottom plan view of the cut tape/leaderless feeder finger depicting the slot relief ( 17 ) for the sprocket that indexes the component carrier tape pass the component opening ( 20 ). The cover tape is only partially detached from the component carrier tape by the cover tape separator ( 12 ). The component carrier tape and partially detached cover tape are directed by the tape guide ( 18 ) and the top support ( 14 ). The partially detached cover tape travels through the guide tunnel ( 15 ) where it is rolled into a tube and folded onto the opposite side of the component carrier tape. Thus, one side of the cover tape is detached from the component carrier tape and folded over onto the other side of the component carrier tape, exposing the underlying components on the component carrier tape. 
         [0029]    Referring to  FIG. 3 , illustrated is the left side plane view of the cut tape/leaderless feeder finger that includes the exit guide ( 21 ) the barrel support ( 23 ) and the clamp relief ( 22 ). The exit guide provides support for the component carrier tape (and tape cover) as it is directed towards the exit on the component feeder, the barrel support ( 23 ) and clamp relief ( 22 ) support the cut tape/leaderless feeder finger when it is attached to the component feeder. 
         [0030]    Referring to  FIG. 4 , illustrated is the right side plane view of the cut tape/leaderless feeder finger with the tape exit guide ( 21 ), the barrel head relief ( 23   a ) and a side view of the cover tape separator ( 24 ) [ FIG. 1  ( 12 )]. The cover tape separator ( 24 ) provides the key function of partially separating the top cover from the substrate and directing the top cover away from the mechanical features of the component feeder. 
         [0031]    Referring to  FIG. 5 , illustrated is the rear view of the cut tape/leaderless feeder finger with the cover tape guide ( 15 ) shown. The cover tape guide is utilized to provide a path through the cut tape/leaderless feeder finger as it is directed towards the exit. 
         [0032]    Referring to  FIG. 6 , illustrated is the front view of the cut tape leaderless feeder finger in this view the tunnel ( 25 ) is shown. The function of the tunnel is to fold and crease the cover tape away from the mechanical features of the component feeder as the tape is indexed towards the exit. 
         [0033]    Referring to  FIG. 7  and  FIG. 8 , illustrated is the top view of the device with an enlarged view of the cover tape separator ( 27 ) [FIG.  1 ( 12 )] and the cover tape top support ( 29 ). The function of the top support ( 29 ) is to hold the undetached side of the cover tape in place as it travels through the tape guide ( 14 ) and into exit tunnel ( 26 ). 
         [0034]    Referring to  FIG. 9 , and  FIG. 10 , illustrated is the feed and peel details as described in the function and operation of the cut tape/leaderless feeder finger. The primary function of the present disclosure is to provide efficient access to electrical components incased in component tape. One of the benefits is the ability to feed component tape without a leader attached. This in turn allows the first component on the reel to be picked which eliminates component waste associated with splicing component tape. This is because a portion of the component carrier tape is not lost in the tape setup required for prior art tape feeders. Moreover, no tape leader portion of any kind is required, thus significantly reducing initial feeder setup time. The feeding and peeling as illustrated here provides access to the component as the component tape ( 33 ) is pushed through the tape guide ( 14 ) and onto the cover tape separator. The undetached side of the cover tape is held in place by the top cover support ( 34 ) where the cover support ( 34 ) supplies pressure to the top cover as it travels through the cut tape/leaderless feeder finger. When the first component ( 31 ) reaches the component opening ( 20 ) the sprocket pins engage the component tape ( 33 ) and the component tape is indexed thru the cut tape/leaderless feeder finger ( 14 ) with each cycle of the component feeder. The process as described reduces feeder setup time and eliminates feeder jams associated with standard, current tape feeders 
         [0035]    Referring to  FIG. 11 , illustrated is an isometric bottom view of the cut tape/leaderless feeder finger detailing the cover tape exit tunnel ( 25 ). The tunnel acts to keep the top cover away from the mechanical features of the component feeder. After each index of the sprocket the component comes to rest at the component opening ( 20 ). The component opening ( 20 ) provides access to the component after the cover tape is removed. The sprocket relief ( 19 ) provides clearance for the sprocket (not shown) to pass through the tape. The tape guide ( 30 ) aligns the tape to engage the sprocket. The cut tape/leaderless feeder finger is attached to the component feeder with a dowel pin, through the pin hole supports ( 23  and  23   a ). The front dowel ( 10 ) is provided to latch the feeder finger in place. 
         [0036]    Referring to  FIG. 12 , illustrated is a typical reel used to supply products such as integrated circuit (IC) chips. The components in the tape are susceptible to contamination by foreign matters, such as dust, for example. Hence, to be protected from foreign matters and for easy handling the IC chips are separately accommodated in an array of accommodating spaces on a carrier of a tape. The tape comprising carrier ( 37 ) and IC chips is wound around a reel ( 35 ) to facilitate handling and transport. The accommodating spaces ( 31 ) of the carrier ( 37 ) are covered with a tape cover ( 32 ). A plurality of transfer holes ( 36 ) are formed at predetermined intervals on one edge of a carrier for advancing the carrier when the reel ( 35 ) is used with a component mounter including a tape feeding unit. Different configurations of component carrier tape can be used and the present disclosure is not to be limited to the type of tape or specific tape feeder embodiments disclosed herein, rather the principals described can be used with any type or configuration of tape feeders and component carrier tape. 
         [0037]    Component tape is supplied to the cut tape/leaderless feeder finger without the requirement of a leader. The component tape  FIG. 12  is fed into the tape guide and onto the cover tape separator. The top cover ( 32 ) is peeled from the component supply tape ( 37 ) on one side by passing the top cover ( 32 ) over the cover tape separator. The component tape is pushed until it reaches the component opening and engages the sprocket pins. As the component tape is indexed through the cut tape/leaderless feeder finger, the top cover is forced over the top cover separator ( 12 ) and into a tunnel ( 15 ) where it is rolled into a tube and creased onto the opposite side of the component carrier tape. The component carrier tape is indexed into a guide that directs it towards the exit of the cut tape/leaderless feeder finger  FIG. 1  and into the exit tube of the component feeder . The empty component tape exits the component feeder with the top cover attached and folded neatly out of the way of the component pocket and index sprocket.