Abstract:
An apparatus that handles a high density of HDA components, integrated circuits or disk-shaped objects is disclosed. The components are stored in at least two different horizontal planes of the tray

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to an apparatus for handling a plurality of electronic components. The apparatus specifically concerns a tray that holds a high density of components used in head disk assemblies, such as media disks, disk clamps, and spacers.  
       BACKGROUND OF THE INVENTION  
       [0002]     Current trays for handling disk drive components are typically limited to holding only 50 components. A typical tray consists of a thermoformed or injection molded tray comprising a matrix of 50 cells formed by five rows and ten columns. A component is placed in each cell. Such prior art trays are limited to holding only 50 components. In addition, the prior art components are vulnerable to misalignment and contamination caused by operators that transfer components from the prior art trays to an automation line. A need exists for a higher density tray with a capacity for handling a larger number of components. A need also exists for trays that reduce the amount of operator intervention, thereby decreasing handling costs and rendering the manufacturing process more efficient.  
       SUMMARY OF THE INVENTION  
       [0003]     The present invention concerns an apparatus for holding a plurality of disks. The apparatus has a first array of protrusions in a first plane that hold disks by positioning a portion of the protrusions through a central opening in each disk. The apparatus also has a second array of protrusions in a second plane, located at a different height than said first plane. Disks can be placed in the second plane by positioning a portion of the protrusions through a central opening in each disk.  
         [0004]     The second array of protrusions is laterally offset from the first array of protrusions by a distance less than the diameter of the disks but greater than the radius of the disks. The first plane is also separated from the second plane by a distance greater than the thickness of the disks.  
         [0005]     In a second embodiment, the invention is directed to a matrix tray that is designed to store components lacking a central opening. Such components are stored in at least two different planes, and may include disk-shaped objects, electronic devices, or integrated circuits. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]      FIG. 1  illustrates a perspective view of the high density tray of the present invention.  
         [0007]      FIG. 2  illustrates an enlarged view of area I of the invention.  
         [0008]      FIG. 3  illustrates a rear view of the enlarged view of  FIG. 2 .  
         [0009]      FIG. 4  illustrates the tray of the invention containing two layers of disks therein.  
         [0010]      FIG. 5A  illustrates a partial sectional view along line V-V of  FIG. 4 .  
         [0011]      FIG. 5B  illustrates a sectional view along line V-V of  FIG. 4 .  
         [0012]      FIG. 6  illustrates a perspective view of the high density tray partially loaded with components that lack a central opening.  
         [0013]      FIG. 7  illustrates the tray of  FIG. 6  partially loaded with semiconductor devices.  
         [0014]      FIG. 8  is a sectional view along line VIII-VIII of the tray in  FIG. 7 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0015]     Referring to  FIGS. 1 and 2 , a generally rectangular tray  100  for handling a plurality of electronic components  15  is shown. In a preferred embodiment the electronic components will have a central opening. Tray  100  has a first array of protrusions  22  in a first plane and a second array of protrusions  33  in a second plane. Each protrusion is a registration point for holding a component in position.  
         [0016]     A matrix of horizontal ribs  28  intersect with vertical ribs  26 . The pitch between rib  26 A and rib  26 B is preferably equidistant throughout the matrix. Similarly, the pitch between horizontal rib  24 A and horizontal rib  24 B is also equidistant.  
         [0017]     In a preferred embodiment, the pitch between vertical ribs  26  is between 19 and 21 mm. In a more preferred embodiment, the pitch between vertical ribs  26  is between 20 and 21 mm. As used herein, pitch refers to the distance between the center of one rib to the center of an adjacent rib.  
         [0018]     The stand-offs  41 ,  43  for holding components in a second plane can be on a portion of ribs  26  or a portion of ribs  28 . In addition, the stand-offs can be on a portion of angled ribs  24 . When present, angled ribs  24  are located within cells  20  formed by intersecting vertical and horizontal ribs. The angled ribs have an oblique angle relative to either rib  26  or rib  28  as shown in  FIG. 3 . In a preferred embodiment, the angled ribs  24  have an acute angle II between 60 and 65 degrees, and an obtuse angle III between 115 and 120 degrees.  
         [0019]     A first array of protrusions  22  are provided in a first plane. By placing the center opening of each component over a protrusion  22 , the disks are oriented along imaginary diagonal lines. This diagonal arrangement alone increases the carrying capacity of the tray from 50 to 67 disks.  
         [0020]     A second array of protrusions  33  are provided for holding a second layer of disks in a second plane within tray  100 . The second array of protrusions  33  is in a second plane that is at a different height than said first plane. As can be seen from  FIG. 2 , protrusions  33  are offset from protrusions  22 . Stand-offs  41  and  43  cooperate with protrusions  33  to second layer disks. The second layer of disks also preferably has a diagonal arrangement.  
         [0021]      FIG. 4  illustrates how a double layer of components would appear in the tray of the present invention. When each position within the two planes is occupied, the maximum density of the tray of the invention is 125 components. This higher density represents more than a two-fold increase over the trays in the prior art.  
         [0022]      FIG. 5A  is a partial cross-section of  FIG. 4  taken alone line V-V. For clarity, only the cross-section of the top tray in  FIG. 4  is shown. Components  15 - 1 ,  15 - 2 , and  15 - 3  are disposed in a first plane having a height H 1 . Components  45 - 1 ,  45 - 2  are disposed within a second plane. The second plane has a height H 2 , which is a height different than H 1  of the first plane.  FIG. 5A  also shows how the first array of protrusions  22  is laterally offset from a second array of protrusions  33 . In this manner, the packing density for electronic components  45  is increased.  
         [0023]     An alternative embodiment of the invention is shown in  FIG. 6 , for components that tack a central opening, such as integrated circuits or circular objects. Any component that has an outer dimension smaller than the dimensions of cell  47  can be handled by tray  300 . The alternative embodiment omits protrusions  22  and  33 , but is similar to tray  100  in nearly all other respects. In place of protrusions  22  and  33 , registration markers  44 , or locating markers, can be provided on tray  300  to identify where each component may be placed. Registration markers in a first plane are located on a vertical or horizontal rib. Registration markers on stand-offs mark the position where components are stored in a second plane at a different height than the first plane. In addition, retaining members such as notches on predetermined standoffs function to retain components  70  in position. The notches are dimensioned to be slightly greater than the thickness of the components and are located on opposing surfaces of the standoffs. In addition, the tray in  FIG. 6  may have an indentation  17  on one side on which an identification label can be placed.  
         [0024]      FIG. 7  illustrates another high density tray, similar to the tray of  FIG. 6 . Tray  150  is partially loaded with electronic components  75 , such as integrated circuits (ICs). Non-limiting examples of ICs that can be handled by the trays of this invention include chips on tape, Very Thin Quad Flat Packs (P-VQFNs), BGAs, Tape-BGAs, or leadless chip packages. Any non-circular component that has an outer dimension smaller than the dimensions of cell  47  can be handled by the tray shown in  FIG. 7 . Optional notches may be provided on more than one side of standoffs  35  to secure the components in their desired position. Component  75  may be supported by additional standoffs  35  where necessary to enhance the stability of the components  75 A and  75 B. Standoffs  35  are preferably located at the juncture of specific angled ribs. A sectional view of  FIG. 7  taken along line VII-VII is provided in  FIG. 8 .  
         [0025]      FIG. 8  illustrates that components  75 A are separated from components  75 B and are laterally offset from each other. Moreover, each layer of components is disposed within a separate plane. Components  75 A- 1 ,  75 A- 2 , and  75 A- 3  are disposed in a first plane having a height H 1 . Components  75 B- 1 ,  75 -B 2 , and  75 B- 3  are disposed within a second plane. The second plane has a height H 2 , which is a height different than H 1  of the first plane.  
         [0026]     In both embodiments of the invention, multiple openings  31  extend through the tray to prevent residue build up during processing. Washing and rinsing steps allow excess particles to be removed through these openings. Accordingly, it is not essential that the trays of the present invention have a solid floor.  
         [0027]     The trays of the present invention can be stacked on top of one another.  FIG. 5B  is a sectional view of two trays loaded with disk clamps  45 . A ridge  27  is located on the periphery of tray  40 - 2  in  FIG. 7 . On the underside of tray  40 - 2  is a recess  29  that conforms in shape and size to ridge  27 . During stacking, ridge  27  of tray  40 - 1  engages with the recess of tray  40 - 2  to form stack  150 . Trays designed to handle ICs in accordance with the second embodiment are also stackable in the manner described above. Prior to shipment, an empty tray is placed at the top of a stack to serve as a protective cover. The stack of trays is then bound with tape and placed in a shipping carton for shipment.  
         [0028]     The present invention is fabricated from traditional methods of injection molding. The present invention can be fabricated from conductive, thermoplastic, non-conductive, and insulated plastic materials. In addition, the trays of this invention can be fabricated from material that has electrostatic dissipating properties.  
         [0029]     The examples described herein are solely representative of the present invention. It is understood that various modifications and substitutions may be made to the foregoing examples without departing from either the spirit or scope of the invention. It is therefore the intent that the invention not be limited to the particular examples disclosed herein.