Abstract:
This abstract is being provided in accordance with the provisions of Section 1.72 of the Rules of Practice in Patent and Trademark Cases (37 CFR). The applicant intends that this abstract be used only to aid in determining the general nature of the technical disclosure. The applicant does not intend that this abstract be looked to in order to aid or assist in the determination of the scope of any claim. 
     An electronics board ( 150 ) is retained by an arrangement of support members ( 120 ) or support pins ( 620 ) during manufacturing operations conducted on the electronics board ( 150 ). The arrangement corresponds to the locations on the electronics board where support members ( 120 ) can be placed without interfering with components mounted to the electronics board ( 150 ). This information is used to form a transparent template ( 110, 610 ) which is placed atop a metallic support plate ( 100 ). In one embodiment of the invention, support members ( 120 ) include a magnetic base which is inserted through the perforations of the support plate ( 100, 500 ). Vacuum driven chucks ( 200 ) are placed on the template ( 110 ) order to restrict the movement of the electronics board ( 150 ) during the application of solder paste to the electronics board ( 150 ). In another embodiment, a template ( 610 ) is used to determine locations for support pins on a support plate ( 500 ) which includes a two-dimensional grid pattern of holes.

Description:
FIELD OF THE INVENTION 
     The invention relates to the field of manufacturing and, more particularly, to a method and apparatus for electronics board retention during various manufacturing operations. 
     BACKGROUND OF THE INVENTION 
     In a high-volume electronics board manufacturing environment, various types of automated equipment are used at different stages in the manufacturing process. For example, a screen printer may be used in order to apply solder paste to a side of an electronics board, while automated pick-and-place equipment is used to place electronic components onto the electronics board. Each of these operations presents challenges in reducing the time and the associated equipment required to prepare the automated equipment to accommodate a particular electronics board. 
     During the application of the solder paste, for example, the screen printer must incorporate a means to retain and support the electronics board so that the viscous solder paste can be applied. This process typically requires a support plate which incorporates support struts which are permanently affixed to the support plate for each type of electronics board. For a two-sided electronics board, a unique support plate is usually required for each side of the electronics board. Thus, in a high mix environment, where many different types of electronics boards are undergoing solder paste screen-printing, a large number of support plates, each with a unique arrangement of support struts, may be required. 
     At another point in the manufacturing process, an electronics board may be placed into an automated pick-and-place machine so that components can be placed on the electronics board. During this stage, the electronics board must also be held into place to ensure that component leads can be subsequently soldered into place. During this operation, a unique support plate is typically required for each type of electronics board being manufactured. Additionally, two such unique support plates may be required when two sided boards are being manufactured. 
     Thus, it is highly desirable to make use of an improved method and apparatus for electronics board retention during manufacturing operations. This can reduce the number of support plates having unique support strut arrangements required to enable solder paste screen-printing and pick-and-place component location for each of the different types of electronics boards being manufactured. Additionally, the method is useful in reducing the setup time required to prepare the equipment to accommodate each type of electronics board. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention is pointed out with particularity in the appended claims. However, a more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the figures, wherein like reference numbers refer to similar items throughout the figures, and: 
     FIG. 1 is an exploded view of an apparatus for electronics board retention during solder paste application in accordance with a preferred embodiment of the invention; 
     FIG. 2 is a cross sectional view of a support member used in an apparatus for electronics board retention during solder paste application in accordance with a preferred embodiment of the invention; 
     FIG. 3 is an exploded view of a vacuum driven chuck used in an apparatus for electronics board retention during solder paste application in accordance with a preferred embodiment of the invention; 
     FIG. 4 is a cross sectional view of the vacuum driven chuck of FIG. 3 in accordance with a preferred embodiment of the invention; 
     FIG. 5 is an elevation view of a solder paste application device in contact with an electronics board and an apparatus for electronics board retention in accordance with a preferred embodiment of the invention; 
     FIG. 6 is a flowchart for a method for determining a support member arrangement used in retaining an electronics board during solder paste application in accordance with a preferred embodiment of the invention; 
     FIG. 7 is a flowchart of another method of retaining an electronics board during application of a solder paste in accordance with a preferred embodiment of the invention; 
     FIG. 8 is an exploded view of an apparatus for electronics board retention during automated component placement in accordance with a preferred embodiment of the invention; and 
     FIG. 9 is a flowchart of a method for determining a support member arrangement used in retaining an electronics board during automated component placement in accordance with an alternate embodiment of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A method and apparatus for electronics board retention during manufacturing operations can eliminate the need for support plates having customized support member arrangements for each electronics board type. This can be especially advantageous in high mix manufacturing environments where many such support plates incorporating unique support member arrangements are needed in order to conduct manufacturing operations on each type of electronics board. Additionally, the method and apparatus can significantly reduce the setup time required to prepare the equipment used in manufacturing operations such as solder paste application and automated component location. The method and apparatus do not require sophisticated tooling and can be used in conjunction with various equipment types used in electronics board manufacturing environments. 
     FIG. 1 is an exploded view of an apparatus for electronics board retention during solder paste application in accordance with a preferred embodiment of the invention. In FIG. 1, electronics board  150  includes first side  152 , and second side  154 . Electronics board  150  preferably incorporates components on both first and second sides  152  and  154 , respectively, thus allowing the most advantageous practice of the inventive principles described herein. However, electronics board  150  may be one-sided without losing the benefits of the inventive principles. Electronics board  150  can be designed to perform a variety of electronic processes and computing, such as signal conditioning, signal processing, power conditioning, or an embedded processing function. Although not shown in FIG. 1, a solder mask is preferably affixed to second side  154  of electronics board  150  in order to facilitate the depositing of solder paste along selected trace patterns, such as those shown in FIG.  1 . 
     Desirably, each of support members  120  includes a magnetic base which is capable of temporarily adhering to support plate  100 . Consequently, it is anticipated that support plate  100  is substantially planar and fabricated using a primarily magnetic material, such as iron or steel. Each of support members  120  also includes a slender upper end which is capable of contacting areas free of electronic components on first side  152  of electronics board  150 . It is generally anticipated that an operator is required to manually determine the locations on first side  152  which can be retained by one of support members  120  without damaging or otherwise affecting the performance of electronics board  150 . Although it is generally expected that the locations on first side  152  are determined manually, nothing prevents the use of a computer in assisting an operator in determining the possible locations of support members  120 . 
     In a preferred embodiment, once the locations on first side  152  of electronics board  150  have been determined, this information is used to determine the locations of perforations  130  in template  110 . Thus, when solder paste is to be applied to second side  154  of electronics board  150 , template  110  can simply be placed atop support plate  100  and held in place by way of guide pins  140  and guide pin holes  145 . Once template  110  is set into place, support members  120  can be adhered to support plate  100  at the correct locations. Electronics board  150  can then be rigidly supported during the application of solder paste to second side  154 . This support is preferably complemented through the use of the vacuum driven chuck described herein with reference to FIG.  3 . Additionally, although not shown in FIG. 1, template  110  desirably includes at least one clip for routing any required vacuum hose from the vacuum driven chuck to an external vacuum source. Further, guide pins  140  and guide pin holes  145  need not be positioned as shown, but may be situated at any convenient location according to the needs of the particular application. 
     In the event that the application of solder paste to first side  152  is required after the application of solder paste to second side  154 , a second template, similar to template  110  but having a different support member arrangement, can be placed atop support plate  100 . In this event, support members  120  can be rearranged as imposed by the second template. Electronics board  150  can then be turned over and rigidly supported by the new arrangement of support members  120  during the application of solder paste to first side  152 . 
     Although the apparatus of FIG.1 is particularly useful when used in conjunction with screen printers which apply solder paste to electronics boards, nothing prevents the use of an apparatus similar to that of FIG. 1 during other manufacturing operations, such as the automated component placement described in reference to FIGS. 8 and 9, herein. 
     FIG. 2 is a cross sectional view of a support member used in an apparatus for electronics board retention during solder paste application in accordance with a preferred embodiment of the invention. In FIG. 2, the base of support member  120  includes magnet  125 , which enables adherence of the support member to a ferromagnetic surface such as support plate  100  of FIG.  1 . Desirably, the remainder of support member  120  comprises aluminum, ceramic, or other nonmagnetic material. This allows the slender end of support member  120  to be placed near magnetic field-generating components resident on electronics board  150  without affecting the performance of these components. 
     FIG. 3 is an exploded view of a vacuum driven chuck used in an apparatus for electronics board retention during solder paste application in accordance with a preferred embodiment of the invention. Although not shown in the exploded view of FIG. 1, vacuum driven chuck  200  is desirably inserted between electronics board  150  and support plate  100  in order to positively retain the electronics board during the application of solder paste to the appropriate side of the electronics board. Desirably, two or more of vacuum driven chucks  200  provide this positive retention with four representing an optimum number. Also not shown in FIG. 1, template  110  incorporates perforations, such as those used to accommodate each of support members  120 , in order to judiciously locate each vacuum driven chuck  200 . 
     The utility of vacuum driven chuck  200  of FIG. 3 is driven by the relatively large viscosity of the solder paste used in a typical screen printer. This excessive viscosity can cause electronics board  150  to remain temporarily adhered to the tool which applies the solder paste. This causes the electronics board to become improperly oriented, thereby allowing solder paste to be unintentionally applied to unsuitable areas of electronics board  150 . 
     Vacuum driven chuck  200  includes hollow body  210 , which includes connector  220 , top surface  230 , and magnetic base  240 . In a preferred embodiment, billowed nozzle  250  fits within top surface hole  235 . Connector  220 , located on a lateral surface of hollow body  210 , conveys a vacuum from the vacuum driven chuck  200  to an external vacuum source. Preferably, connector  220  includes a means for coupling to the vacuum hose such as annular barb  225 . Thus, when the vacuum is applied, the preferably elastic nature of billowed nozzle  250  contracts and forms a seal which retains electronics board  150  while the solder paste is applied. 
     To enhance the capability to retain an electronics board, top surface  230  preferably includes a chamfered edge which restricts the lateral movement of the electronics board during the solder paste application process. Although it is desirable that hollow body  210  is substantially cylindrical, nothing prevents hollow body  210  from being shaped in accordance with a polygon, such as a hexagon. Further, although described in an environment which includes vacuum driven chuck  200  retaining an electronics board, nothing prevents the use of vacuum driven chuck  200  in retaining other articles of manufacture in found in other manufacturing environments. 
     FIG. 4 is a cross sectional view of the vacuum driven chuck of FIG. 3 in accordance with a preferred embodiment of the invention. The cross sectional view of FIG. 4 shows the elements of FIG. 3, and further shows magnetic insert  245  which inserts into magnetic base  240 . Additionally, the chamfered top surface of the vacuum driven chuck is shown in greater detail as well. 
     FIG. 5 is an elevation view of a solder paste application device in contact with an electronics board and an apparatus for electronics board retention in accordance with a preferred embodiment of the invention. In FIG. 5, support members  120  have been placed atop support plate  100  by way of template  110 . In order to positively retain electronics board  150 , two vacuum driven chucks  200  have been inserted between the electronics board and the support plate. Solder paste application device  160  is shown in contact with the second side of electronics board  150 . Desirably, each of vacuum driven chucks  200  is coupled to a separate vacuum source, thus eliminating the possibility that the loss of integrity of the seal which billowed nozzle  250  makes with electronics board  150  will negatively impact other, similar vacuum driven chucks. 
     FIG. 6 is a flowchart for a method for determining a support member arrangement used in retaining an electronics board during solder paste application in accordance with a preferred embodiment of the invention. At step  300 , an electronics board is placed into a set up fixture. It is anticipated that step  300  takes place offline of any automated manufacturing equipment. The method continues at step  310 , where a substantially blank transparent template is overlaid on the electronics board. This overlaying allows an operator, perhaps assisted by a computer, to determine (at step  320 ) the locations on the electronics board at which support members can be placed without interfering with electronics components located on the first side of the electronics board. At step  330 , the substantially transparent blank template is perforated in order to form a perforated template. The method continues at step  340  where the perforated template is placed onto a support plate. At step  350 , the support members are inserted through the perforations of the perforated template and adhered to an underlying support plate. 
     FIG. 7 is a flowchart of another method of retaining an electronics board during application of a solder paste in accordance with a preferred embodiment of the invention. The apparatus of FIG. 1 using the vacuum driven chuck of FIG. 3 is suitable for performing the method of FIG.  7 . The method begins at step  400 , where a perforated template is placed atop a support plate. Preferably, the template of step  400  includes perforations corresponding to support locations on the electronics board as well as perforations corresponding to suitable locations where vacuum driven chucks can be used to positively retain the electronics board during the application of solder paste to the electronics board. At step  410 , support members and vacuum driven chucks are placed through the corresponding holes of the template of step  400  and adhered to a support plate. At step  420 , the electronics board is placed atop the support members. At step  430 , solder paste is applied to a second side of the electronics board. 
     FIG. 8 is an exploded view of an apparatus for electronics board retention during automated component placement in accordance with a preferred embodiment of the invention. In FIG. 8, support plate  500  is similar to support plate  100  of FIG. 1 with the exception that support plate  500  includes a grid perforation pattern, wherein a perforation or hole is present at regular horizontal and vertical intervals of the support plate. For a particular electronics board, such as electronics board  150  of FIG. 1, template  610  is used to identify those locations on support plate  500  where support pins  620  can be placed in order to support the electronics board during automated placement of components on the second side of electronics board  150 . 
     In a preferred embodiment, template  610  is fabricated by placing a substantially transparent blank template over first side  152  of electronics board  150 . This blank template includes a grid pattern which substantially embodies or represents the grid perforations pattern of support plate  500 . With the blank template overlaid atop the first side of electronics board  150 , the grid locations where support pins  620  can be placed is then determined. Template  610 , which includes only the perforations appropriate to support electronics board  150 , is then created. Template  610  is then placed over support plate  500  and held in place by way of guide pins  640  and guide pin holes  650 , shown in a representative location in FIG.  8 . Support pins  620  are then placed into support plate  500  at the appropriate locations imposed by template  610 . Template  610  can then be removed and electronics board  150  retained while solder paste is applied to second side  154 . 
     Although the apparatus of FIG. 8 is particularly useful when used in conjunction with automated component placement, nothing prevents the use of an apparatus similar to that of FIG. 8 during other manufacturing operations, such as screen printers which apply solder paste to electronics boards described in reference to FIGS. 1 and 5, herein. 
     FIG. 9 is a flowchart of a method for determining a support member arrangement used in retaining an electronics board during automated component placement in accordance with an alternate embodiment of the invention. The method begins at step  700  where a transparent grid is overlaid atop a first side of an electronics board. Preferably, the substantially transparent grid includes perforations at each grid location, wherein the grid location substantially embodies the grid perforation pattern of a support plate. The method continues at step  710 , where a determination is made as to the support pin locations appropriate for the first side of the electronics board. Preferably, these pin locations correspond to areas not populated by electronics components on the electronics board. 
     The method continues at step  720  where a template, which incorporates perforations at the support pin locations determined at step  710 , is placed atop the support plate. Also in step  720 , support pins are placed within the support plate at the locations dictated by the template. At step  730 , the template is removed, and an electronics board is placed atop the support pins. The electronics board may then be held into place by way of a clamp or other means of restricting lateral movement of the electronics board. 
     In conclusion, a method and apparatus for electronics board retention during manufacturing operations can eliminate the need for support plates having customized support member arrangements for each electronics board type. Thus, a single support plate and a small set of support members or support pins can replace a large number of customized support plates and permanently affixed support struts used in several manufacturing operations. This can be especially advantageous in high mix manufacturing environments where many such support plates incorporating unique support member arrangements are needed in order to conduct manufacturing operations on each type of electronics board. Additionally, the method and apparatus can significantly reduce the setup time required to prepare the equipment used in manufacturing operations such as solder paste application and automated component location. The method and apparatus do not require sophisticated tooling and can be used in conjunction with various equipment types used in electronics board manufacturing environments. 
     Accordingly, it is intended by the appended claims to cover all modifications of the invention that fall within the true scope and spirit of the invention.