Abstract:
Provided is an alignment mechanism for aligning a lamination film with a carrier substructure prior to laminating the film to the substructure to form a carrier for integrated circuits. The substructure and the lamination film define complementary perforations and a plurality of respective fiducials. The alignment mechanism includes a sensor arrangement configured to detect the fiducials in the lamination film and substructure and a displacement mechanism configured to displace the lamination film with respect to the substructure to align the perforations of the film and substructure respectively according to alignment of their fiducials so that a printing fluid can pass through the perforations in the film and the substructure of the carrier. The mechanism also includes a controller configured to control operation of the sensor arrangement and the displacement mechanism.

Description:
FIELD OF INVENTION 
       [0001]    The invention relates to the field of printing, in general. More specifically, the invention provides for a laminating apparatus for laminating a printhead integrated circuits (IC) carrier sub-assembly; a method for laminating a carrier for printhead integrated circuits; a safety system for an apparatus used to bond an integrated circuit carrier film to a base assembly of a carrier used for testing integrated circuits; a bonding apparatus for bonding a carrier sheet used for carrying printhead integrated circuits to be tested to a carrier base; and an alignment mechanism for aligning a lamination film with a carrier substructure prior to laminating the film to the substructure to form a carrier for integrated circuits. 
       CO-PENDING APPLICATIONS 
       [0002]    The following applications have been filed by the Applicant simultaneously with the present application: 
         [0000]                                                        MPN023US   MPN024US   MPN025US   MPN026US   MPN027US   MPN028US   MPN029US       MPN030US   MPN031US   MPN032US   MPN033US   MPN034US   MPN035US   MPN036US       MPN037US   MPN038US   MPN039US   MPN041US   MPN043US   MPN046US   MPN047US       MPN048US   MPN049US   MPN051US   MPN052US   MPN053US   MPN054US   MPN055US       MPN056US   MPN057US   MPN058US   MPN059US   MPN060US   MPN061US                    
The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned.
 
       CROSS REFERENCES 
       [0003]    The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference. 
         [0000]    
       
         
               
               
               
               
               
               
               
             
           
               
                   
               
             
             
               
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       BACKGROUND 
       [0004]    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. 
         [0005]    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. 
         [0006]    Some form of carrier is generally required for testing such integrated circuits. The carrier is required to be suitable for the attachment of printhead integrated circuits. 
       SUMMARY 
       [0007]    According to a first aspect of the invention there is provided a laminating apparatus for laminating a printhead integrated circuit (IC) carrier sub-assembly and a lamination film, said apparatus comprising: 
         [0008]    a lamination support for receiving the carrier; 
         [0009]    a lamina supply for supplying a lamina defining said lamination film; 
         [0010]    an alignment mechanism configured to align the lamination film with the IC carrier sub-assembly; 
         [0011]    a bonding apparatus configured to bond the lamination film to the IC carrier sub-assembly; and 
         [0012]    a control system to control operation of the lamina supply, alignment mechanism and bonding apparatus to facilitate automatic bonding of the lamination film to the surface of the carrier. 
         [0013]    The lamina supply may include a lamina film reel on which the lamina is stored and a film gripper assembly to grip the lamina for positional adjustment by the alignment mechanism. 
         [0014]    The lamina supply may be configured to supply a lamina selected from the group consisting of: a thermosetting adhesive film, a polyimide carrier with adhesive on both sides thereof, and film with a polyethylene terephthalate (PET) liner. 
         [0015]    The alignment mechanism may include a digital camera arrangement to sense relative positions of fiducials on the carrier sub-assembly and the lamination film. 
         [0016]    The alignment mechanism may include actuators configured to displace the lamination support relative to the supplied lamina to facilitate alignment of the fiducials. 
         [0017]    The bonding assembly may include a heated lamination plate to bond the supplied lamina thermally to the carrier sub-assembly. 
         [0018]    The bonding assembly may include two film reels positioned on opposite sides of the heated lamination plate to dispense a thermal interface tape across said plate to facilitate uniform heat and pressure distribution during bonding. 
         [0019]    The control system may include an operator interface allowing an operator to control the laminating apparatus. 
         [0020]    The apparatus may include a cutting mechanism for cutting excess lamina from the carrier sub-assembly to minimize subsequent particulate contamination of carriers prior to bonding. 
         [0021]    According to a second aspect of the invention there is provided a method for laminating a carrier for printhead integrated circuits, said carrier including a plurality of fiducials, the method comprising the steps of: 
         [0022]    receiving the carrier in a cradle platform; 
         [0023]    aligning each said fiducial with respective fiducials in a lamina having a series of such holes therein; and 
         [0024]    bonding the aligned lamina to the carrier, so that a printing fluid is able to pass through the laminated apertures after such bonding. 
         [0025]    The step of receiving the carrier may include receiving a carrier molded from a liquid crystal polymer (LCP). 
         [0026]    The step of receiving the carrier may include receiving a carrier having a plurality of discrete fluid paths terminating in the surface of the carrier to define said respective fiducials. 
         [0027]    The method may include a step of supplying the lamina from a spool. 
         [0028]    The step of supplying the lamina may include de-ionizing the lamina with a de-ionizer to reduce electrostatic charge on the lamina prior to bonding. 
         [0029]    The step of aligning may include sensing relative positions of the fiducials and displacing the lamina with respect to the carrier to align the fiducials. 
         [0030]    The step of bonding may include thermally bonding the lamina to the carrier. 
         [0031]    The step of bonding may include supplying a thermal interface material between a bonding assembly and the carrier to ensure uniform heat distribution during bonding. 
         [0032]    The method may include a step of cutting excess lamina from the carrier. 
         [0033]    The step of cutting may include cutting with an ultrasonic knife to minimize subsequent particulate contamination of carriers prior to bonding. 
         [0034]    According to a third aspect of the invention there is provided a safety system for an apparatus used to bond an integrated circuit carrier film to a base assembly of a carrier used for testing integrated circuits, the apparatus including fluid-driven actuators for actuating movable components, heating circuits for heating bonding components within an operational zone and an electrical power supply, said system comprising: 
         [0035]    a sensor arrangement for sensing an operational status of the apparatus; 
         [0036]    an emergency cut-off configured to deactivate the apparatus when an undesired operational status is sensed; and 
         [0037]    a controller operatively connected to both the sensor arrangement and the emergency cut-off to control operation thereof. 
         [0038]    The sensor arrangement may be configured to sense an operational status selected from the group consisting of: a position of at least one of the movable components of the laminator; a temperature of at least one of the bonding components of the laminator; a presence of a foreign object proximate a movable or heated component; a fluid pressure of the actuators; a presence of the base assembly; authenticity of the base assembly; a presence of the integrated circuit carrier film; an alignment of the base assembly with the integrated circuit carrier film; and the electrical power supply. 
         [0039]    The sensor arrangement may include a plurality of micro-switches for sensing the position of the movable components. 
         [0040]    The sensor arrangement may include a temperature sensor for sensing the temperature of the heated component. 
         [0041]    The sensor arrangement may include a light curtain assembly arranged on the apparatus to sense the ingress of a foreign object into the operational zone. 
         [0042]    The sensor arrangement may include a pressure sensor to sense the fluid pressure of the actuators. 
         [0043]    The sensor arrangement may include a base assembly sensor to sense the presence of the base assembly. 
         [0044]    The sensor arrangement may include a barcode scanner to scan a barcode of the base assembly to verify the authenticity thereof. 
         [0045]    The sensor arrangement may include an integrated circuit carrier film sensor to sense the presence of the integrated circuit carrier film. 
         [0046]    The sensor arrangement may include an alignment sensor to sense an alignment of the integrated circuit carrier film relative to the support. 
         [0047]    The sensor arrangement may include an electricity sensor to monitor the electrical power supply. 
         [0048]    According to a fourth aspect of the invention there is provided a bonding apparatus for bonding a carrier sheet used for carrying printhead integrated circuits to be tested to a carrier base, said apparatus comprising: 
         [0049]    a support assembly configured to receive and support the carrier base; 
         [0050]    a lamination head arranged on the support assembly and configured to bond the carrier sheet to the carrier base; 
         [0051]    a conformal material supply mechanism arranged on the support assembly and configured to interpose a conformal material between the surface and the head prior to bonding; and 
         [0052]    a controller to control operation of the lamination head and the supply mechanism to facilitate bonding of the carrier sheet to the carrier base. 
         [0053]    The head may include a heated platen configured to bear against the carrier sheet for thermally bonding the carrier sheet to the carrier base. 
         [0054]    The head may include a temperature sensor to sense a temperature of the heated platen, the temperature sensor being connected to the controller to control a temperature of the heated platen. 
         [0055]    The head may include a pressure sensor to sense a pressure which the heated platen applies during bonding, the temperature sensor being connected to the controller to control a pressure applied by the heated platen. 
         [0056]    The conformal material supply mechanism may include a feed reel and a take-up reel respectively located on opposite sides of the lamination head, to feed the conformal material across the heated platen. 
         [0057]    The conformal material supply mechanism may include an incremental sensor to sense a length of the material fed across the heated platen. 
         [0058]    According to a fifth aspect of the invention there is provided an alignment mechanism for aligning a lamination film with a carrier substructure prior to laminating the film to the substructure to form a test carrier for integrated circuits, the substructure and the lamination film defining complementary perforations and a plurality of respective fiducials, said alignment mechanism comprising: 
         [0059]    a sensor arrangement configured to detect the fiducials in the lamination film and substructure; 
         [0060]    a displacement mechanism configured to displace the lamination film with respect to the substructure to align the perforations of the film and substructure respectively according to alignment of their fiducials so that a printing fluid can pass through the perforations in the film and the substructure of the test carrier; and 
         [0061]    a controller configured to control operation of the sensor arrangement and the displacement mechanism. 
         [0062]    The displacement mechanism may include actuators configured to displace the substructure relative to the lamination film along at least two axes. 
         [0063]    The actuators may be in the form of a number of linear actuators that operatively engage the substructure to displace it along one axis and a number of linear actuators that operatively engage the lamination film to displace it along an orthogonal axis. 
         [0064]    The sensor arrangement may include a digital camera and lens arrangement in signal communication with the controller for identifying the fiducials. 
         [0065]    The digital camera and lens arrangement may be configured to identify fiducials in the form of complementary openings defined in the substructure and the lamination film. 
         [0066]    The alignment mechanism may include an operator interface operatively connected to the controller and configured to receive displacement instructions from an operator. 
         [0067]    The displacement mechanism may be configured to displace the lamination film incrementally relative to the carrier or lamina, respectively. 
         [0068]    According to a sixth aspect of the invention there is provided a software product for execution by a controller of a laminating apparatus, as described above, said software product enabling the apparatus to perform a method having the steps of: 
         [0069]    receiving the carrier in a cradle platform; 
         [0070]    aligning each said fiducial with respective fiducials in a lamina having a series of such holes therein; and 
         [0071]    bonding the aligned lamina to the carrier, so that a printing fluid is able to pass through the laminated apertures after such bonding. 
         [0072]    According to a seventh aspect of the invention there is provided a computer readable memory incorporating a software product, as described above. 
         [0073]    Embodiments of the invention are now described, by way of example, with reference to the accompanying drawings. The following description is intended to illustrate particular embodiments of the invention and to permit a person skilled in the art to put those embodiments of the invention into effect. Accordingly, the following description is not intended to limit the scope of the preceding paragraphs in any way. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0074]    In the accompanying drawings: 
           [0075]      FIG. 1  shows a perspective view of an embodiment of a carrier without lamination film to which a lamination film is to be bonded with a laminating apparatus in accordance with one embodiment of the invention. 
           [0076]      FIG. 2  shows a perspective view of the embodiment of the carrier of  FIG. 1  with the lamination film bonded thereto, in accordance with one embodiment of the invention. 
           [0077]      FIG. 3  shows a front perspective view of one embodiment of a laminating apparatus, in accordance with the invention. 
           [0078]      FIG. 4  shows an operator interface of the apparatus of  FIG. 3 . 
           [0079]      FIG. 5  shows an operator display panel of the apparatus of  FIG. 3 . 
           [0080]      FIG. 6  shows a closer view of an alignment mechanism, in accordance with one embodiment of the invention, of the apparatus of  FIG. 3 . 
           [0081]      FIG. 7  shows a perspective view of lamination support or cradle platform, in accordance with one embodiment of the invention, for operatively receiving the carrier of  FIG. 1 . 
           [0082]      FIG. 8  shows a closer perspective view of the lamina supply of the alignment mechanism of  FIG. 6 . 
           [0083]      FIG. 9  shows a side schematic view of the lamina supply of  FIG. 8 . 
           [0084]      FIG. 10  shows an embodiment of an optical assembly of the alignment mechanism of  FIG. 6 . 
           [0085]      FIG. 11  shows a closer perspective view of the bonding apparatus of  FIG. 6 . 
           [0086]      FIG. 12  shows a side perspective view of the bonding apparatus of  FIG. 6 . 
           [0087]      FIG. 13  shows a detail view of the bonding apparatus of  FIGS. 11 and 12 . 
           [0088]      FIG. 14  shows a top diagrammatic view of the apparatus of  FIG. 6 , showing respective axial orientations of motors for the alignment mechanism of  FIG. 6 . 
           [0089]      FIGS. 15A and 15B  show an example of an alignment process displayed by the operator display panel. 
           [0090]      FIG. 16  shows a front view of an open service enclosure of the apparatus of  FIG. 3 . 
           [0091]      FIG. 17  shows a rear view of an open service enclosure of the apparatus of  FIG. 3 . 
           [0092]      FIG. 18  shows an inner schematic view of a lower rear open service enclosure of the apparatus of  FIG. 3 . 
           [0093]      FIG. 19  shows an outside view of the service enclosure of  FIG. 17 . 
           [0094]      FIG. 20  shows a close-up view of a cutting assembly of the apparatus of  FIG. 1 . 
           [0095]      FIG. 21  shows a block diagram representing a method of laminating the carrier, in accordance with one embodiment of the invention, with the apparatus shown in  FIG. 3 . 
           [0096]      FIG. 22  shows a functional block diagram of a laminating process performed by the apparatus of  FIG. 3 . 
           [0097]      FIG. 23  shows a control layout of a safety system, in accordance with one embodiment of the invention, of the apparatus shown in  FIG. 3 . 
           [0098]      FIG. 24  shows a programmed logic controller (PLC) layout of the apparatus shown in  FIG. 3 . 
           [0099]      FIG. 25  shows a control layout of a heater cylinder, a positioning cylinder, ultrasonic knife cylinders and carrier and film or tape grippers of the apparatus of  FIG. 3 . 
           [0100]      FIG. 26  shows a network control layout of the apparatus of  FIG. 3 . 
           [0101]      FIG. 27  shows a power layout for ultrasonic knives of the apparatus of  FIG. 3 . 
           [0102]      FIG. 28  shows a control layout of a first motor or actuator of the apparatus of  FIG. 3 . 
           [0103]      FIG. 29  shows a control layout of a second motor or actuator of the apparatus of  FIG. 3 . 
           [0104]      FIG. 30  shows a control layout of a third motor or actuator of the apparatus of  FIG. 3 . 
           [0105]      FIG. 31  shows a control layout of a fourth motor or actuator of the apparatus of  FIG. 3 . 
           [0106]      FIG. 32  shows a control layout of a fifth motor or actuator of the apparatus of  FIG. 3 . 
           [0107]      FIG. 33  shows a control layout of a sixth motor or actuator of the apparatus of  FIG. 3 . 
           [0108]      FIG. 34  shows a control layout of a seventh motor or actuator of the apparatus of  FIG. 3 . 
           [0109]      FIG. 35  shows a control layout of a film liner take-up motor of the apparatus of  FIG. 3 . 
           [0110]      FIG. 36  shows a control layout of a heater tape feed motor of the apparatus of  FIG. 3 . 
           [0111]      FIG. 37  shows a control layout of a heater tape tension motor of the apparatus of  FIG. 3 . 
           [0112]      FIG. 38  shows a control layout of a heater tape encoder motor of the apparatus of  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION 
       [0113]    Aspects of the invention will now be described with reference to specific embodiments thereof. Reference to “an embodiment” or “one embodiment” is made in an inclusive rather than a restrictive sense. As such, reference to particular features found in one embodiment does not exclude those features from other embodiments. 
       Carrier Overview 
       [0114]    In broad aspects, the invention relates to bonding a lamina film to a carrier  10 , an example of which is shown in  FIG. 1 . The carrier  10  is generally an assembly of two liquid crystal polymer (LCP) micro-moldings  11   a  and  11   b . The micro-moldings  11  define a plurality of discrete tortuous ink paths for ducting ink from an ink reservoir (not shown) to a printhead integrated circuit (not shown). 
         [0115]    Accordingly, the carrier  10  is used to test the operation of such printhead integrated circuits (IC) prior to assembling such an IC into a printer or printing equipment. Given the operation of these printhead IC&#39;s, it is generally necessary to establish a seal between the tortuous ink paths defined in the carrier  10  and fluid inlets of the IC. For this reason, the Inventor has found that by laminating the carrier  10  with a lamina film  14 , such a fluid tight seal can be established between the carrier  10  and IC when the IC is fastened to the carrier  10 . This helps to ensure that ink is supplied to the printhead ICs in a leak-free manner. 
         [0116]    The ink paths through the carrier  10  typically terminate as fiducial apertures or “fiducials”  12  in a surface of the carrier  10 , shown in  FIG. 1 . It is therefore necessary to bond the lamina  14  to the carrier  10  without blocking or impeding these fiducials, otherwise ink will be prevented from flowing through the carrier  10  to the printhead ICs. An example of a carrier  10  having the lamina  14  applied is shown in  FIG. 2 . It is clearly shown that the fiducials  12  are not blocked to ensure proper ink supply. 
         [0117]    The carrier  10  also defines two locating openings  13  at respective opposite ends, as shown. The purpose of the locating openings  13  is to fix and align the carrier accurately prior to the laminating process. Details of such laminating are made clear in the following description. 
       Apparatus Overview 
       [0118]      FIG. 3  shows one embodiment of an apparatus  16  for accurately aligning the fiducials  12  with corresponding apertures in the lamina film  14 . The apparatus  16  can also bond the lamina  14  to the carrier  10  once proper alignment has been achieved. The apparatus  16  includes, inter alia, a support structure  17  defining an enclosure which houses a laminating support or cradle platform  18 , as well as a lamina supply  20 , an alignment mechanism  22 , bonding apparatus  24 , and a controller or control system  26  (described below with reference to control layout  FIGS. 23 to 38 ) operatively controlling these components. These components are positioned on a floor portion  19  of the apparatus  16 , as shown. Also included is an operator control panel  28  and an operator display panel  30  enabling an operator to regulate and manage the operation of the controller  26 , and hence the apparatus  16 . 
         [0119]    The apparatus  16  also includes a safety system  31 , typically implemented via the controller  26 , described in more detail below with reference to  FIG. 23 . One feature of the safety system is a light curtain  40  and a warning beacon  42 , shown in  FIG. 3 . The beacon  42  includes a stack light display, with different coloured lights indicating different operational states of the apparatus  16 . The enclosure has a number of service panels covering control components housed in the enclosure, namely a front equipment enclosure  32 , a rear equipment enclosure  34 , and a lower rear equipment enclosure  36 . These components are discussed in more detail below. 
         [0120]    The apparatus  16  also has a barcode scanner  38 , which is used to scan a barcode of the carrier  10 . The controller  26  is typically arranged in signal communication with a remote monitoring system or RMS (not shown). This remote monitoring system can be connected to a number of semi-autonomous apparatus, machines or devices involved in the assembly, manufacture or testing of the carrier  10  and/or other equipment involving the carrier  10  or IC&#39;s. The remote monitoring system is able to keep track of all the carriers assembled in this manner, which allows quality and assurance control of such an assembly process. 
         [0121]    For example, if each device forming part of such an assembly process scans and uploads a barcode of the carrier  10 , or of parts forming the carrier  10 , then the remote monitoring system can prevent further assembly of a carrier or parts which are not standard or are inferior. In the case of the apparatus  16 , if the carrier  10  is successfully laminated, as described below, then the remote monitoring system will log the barcode of the successfully laminated carrier  10  to allow further devices, such as an IC attaching machine, to further process the carrier  10 . Similarly, if the apparatus  16  fails to laminate the carrier  10  successfully, the remote monitoring system can log the barcode of the particular carrier as inferior to prevent further machines from processing such a sub-standard carrier. 
       Operator Control Panel 
       [0122]    The operator control panel is shown in  FIG. 4 . In the embodiment shown, the control panel  28  includes two start buttons  44 . 1  and  44 . 2 . These start buttons  44  are spaced apart to prevent accidental activation of the apparatus  16 . The start buttons  44  also ensure that both arms of the operator are kept away from moving components of the apparatus  16  when the apparatus  16  is initiated. Thus, an operator must generally deliberately press both buttons  44  simultaneously to start the apparatus  16 . The panel also includes a reset button  50  to reset the apparatus to an idle state, and a scan button  46  which activates the barcode scanner  38 . An emergency stop button  48  instructs the controller  26  to halt all operation of the apparatus  26 . As such, it is to be appreciated that the buttons are all linked to the controller  26 , which is responsible for the operation of the apparatus  16 , as will be described below. 
         [0123]    The lamination process is a semi-automated process under control of the controller or control system  26 . The operator generally manages the operation of the controller  26  via the operator control and display panels  28  and  30 . The operator is generally tasked with inserting the carrier  10  into a nest formation  235  ( FIG. 7 ) on the support platform  18  of the apparatus  16 , and removing the carrier  10  once the lamina  14  has been applied to said carrier  10 . General maintenance and overseeing, such as monitoring of a lamina supply, correct alignment, etc. are the responsibility of the operator. 
         [0124]    The reset, start and scan buttons  50 ,  46  and  44 , respectively, are flush, momentarily illuminated, coloured lens push buttons having normally open switches. The emergency stop button  48  is a 40 mm, twist and pull to release, non-keyed heavy duty operating button with a normally closed switch. The Inventor has found buttons manufactured by Sprecher and Schuh to be suitable. 
         [0125]    The operator interface panel  28  also includes a pressure regulator  52  for an ultrasonic knife assembly  86  and a platen pressure regulator  54  for the bonding apparatus  24 , described in more detail below. The apparatus  16  includes electrically as well as pneumatically actuated components to effect movement of the relevant components. The regulators  52  and  54  allow the operator to monitor pneumatic pressure in such pneumatically actuated components. 
       Display Panel 
       [0126]    The apparatus  16  also includes the display panel  30 , shown in  FIG. 5 , via which the operator is shown an operational status of the apparatus  16 . In the embodiment shown, the panel  30  includes a computer with integrated flat panel display  56  along with a number of sensor indicators. The sensors on the panel  30  include a pressure sensor of the bonding mechanism  24 , a main system pressure sensor  62 , a pressure sensor for a clamp  64  clamping the carrier  10  to the cradle platform  18 , and a pressure sensor for the knife assembly  86 . There are also pressure regulators on the panel  30 , namely a pressure regulator  70  for the clamps of the cradle assembly  18 , and a main system pressure regulator  58  for a pneumatic system of the apparatus  16 . The panel  30  also includes locking handles  68  for opening the panel  30  to reveal the inner enclosure shown in  FIG. 16 , described below. 
         [0127]    In the embodiment shown, the pressure sensors  60 ,  62 ,  64  and  66  are SMC ISE40 digital pressure sensors to provide readouts for the different portions of a pneumatic system of the apparatus  16 . The pressure regulators  58  and  70  are SMC AR29K-02H pressure regulators. The touch panel with computer is an Advantech® resistive analog touch screen with an integrated PC with a Pentium® IV processor. 
       Alignment and Laminating Arrangement 
       [0128]    The lamination support or cradle platform  18 , lamina supply  20 , alignment mechanism  22 , and bonding apparatus  24  are shown in more detail together in  FIG. 6 . These components  20 ,  22  and  24  together constitute an alignment and laminating arrangement. The individual components are described in more detail below. 
         [0129]    As mentioned above, the apparatus  16  includes the support structure  17  with a floor  19  mounted in said support structure  17  to define a planar support surface or floor  19 . As shown, the table  21  is mounted on the floor  19  via a pair of spaced support rails  23  to form a table assembly  72 . A table actuator  84  is fast with the floor  19  and connected to the table  21  to displace the table  21  along the rails  23  in a Z-axis direction, under control of the control system  26 . A pair of Z-axis guide rails  25  is also mounted on the table  21 . By having the table  21  mounted on the floor  19  in such a manner, the table assembly  72  can slide in and out of the apparatus  16  to allow an operator easier access when loading or unloading the carrier  10  into the cradle platform  18  of the apparatus  16 . The guide rails  25 , in turn, enable the controller  26  to align the fiducials of the carrier with the apertures in the lamina film  14 . The different components of the laminating arrangement will now be described. 
       Lamination Support 
       [0130]    The lamination support, stage or cradle  18  is mounted on the table  21  and is shown in more detail in  FIG. 7 . The stage  18  has a pair of spaced guide feet  27  in which respective guide rails  25  of table  21  can be slid. A pneumatic linear stage actuator  80  is fast with the table  21  and is connected to the stage  18  to displace the stage  18  along the Z-axis, under control of the control system  26 . 
         [0131]    The stage  18  can be moved by the control system  26  along the guide rails  25  for aligning the lamina  14  with the carrier  10  under a camera arrangement  76  ( FIG. 10 ). The actuator  80  enables fine and precise movements of the carrier  10  to facilitate the alignment of the microscopic fiducials of the carrier  10  with the apertures in the lamina  14 . 
         [0132]    The stage  18  defines a nest formation  235  in which the carrier  10  is received, in use. A pair of spaced locating pins  230  extends from the stage  18 , in the formation  235 , to be received in the locating openings  13  defined in the carrier  10 . A manually adjustable stop member  232  is also positioned on the stage  18  to ensure that the carrier  10  is correctly aligned when the pins  230  are received through the openings  13 . 
       Lamina Supply 
       [0133]    The lamina supply  20  is shown in more detail in  FIGS. 8 and 9 . Broadly, the lamina supply  20  provides the lamina film  14  for bonding to the carrier  10 , in use. The alignment mechanism  22  (described below) aligns the supplied lamina  14  over the carrier  10 , so that the fiducials  12  line up with corresponding apertures in the lamina.  14 . Once aligned, the bonding apparatus  24  bonds the lamina  14  to the carrier  10 . The stage  18  mounted to the table  21  is moved with the table assembly actuator  84 , under control of the control system  26 , below the bonding apparatus  24  for the bonding process. 
         [0134]    The lamina supply  20  features a lamination film reel  94 , a film gripper assembly  96 , and an ionizer bar  98 . The lamina supply  20  also includes a removal roller  120 , and a liner take-up spool  122 . In one embodiment, the lamina film  14  is approximately 11 mm wide and consists of a 50 μm polyimide carrier with 25 μm of adhesive on both sides thereof. The film  14  also has a 12.7 μm PET liner  15  on the side of the carrier  10 , which liner  15  is removed at the removal roller  120  prior to lamination. The liner  15  is wound up on take-up spool  122  for later disposal. A cleaning roller  124  removes loose particles from the film, and an ionizer bar  98  reduces a static charge which may be present on the lamina film  14  due to the removal of the liner  15 , to prevent attracting further loose particles. A pinch roller  126 , which drives the cleaning roller  124 , and a static film gripper  128  facilitate feeding of the lamina film  14  to a film gripper  130 . The film gripper  130  operatively feeds the lamina film over the platform  18  with the carrier  10  positioned thereon. 
         [0135]    In use, drives, actuators or motors  110  and  108  drive the lamina  14  to the film gripper assembly  96 , under control of the control system  26 . Similarly, the liner  15  is wound up on take-up spool  122  by drive  114 , under control of the control system  26 . The static film gripper  128  includes a tape sensor  97  which is monitored by the control system  26 . The lamina  14  is fed through the static film gripper  128  by drive  108  and pinch roller  126 , as shown. Once a sufficient length of film has been fed to the film gripper  130 , the film gripper  130  is actuated by control system  26  to grip this length of lamina. A film gripper drive mechanism  74  includes a gripper rail  75  on which the film gripper  130  runs. The film gripper  130  is driven along the rail  75  by means of a drive belt  129  actuated by an actuator or motor  106  under control of the control system  26 . 
         [0136]    The film gripper  130  grips the lamina film supplied from the spool or lamination film reel  94  and pulls it though the static film gripper  128  when the drive belt  129  is actuated by the actuator  100 . When a sufficient amount of film has been pulled across the cradle  18 , (as determined by gripper position sensors on the rail  75 ) under control of the control system  26 , the gripper  130  stops and the static film gripper  128  grips the film so that the lamina is securely held by both grippers  128  and  130 . The film pulled across the carrier  10  in the cradle  18  is then aligned by means of the camera arrangement  76  and actuators  102 ,  104  and  100  ( FIG. 14 ), described in more detail below. 
       Camera Arrangement 
       [0137]    Referring now to  FIG. 10 , the camera arrangement  76  includes cameras  90  arranged in signal communication with the controller or control system  26  by means of Firewire connectors  132 . The camera arrangement  76  also includes telecentric lenses  134  for focusing the cameras  90 . Also included are LED assemblies  92 , having LEDs  138  supported on LED support frames  140 , for illuminating the film  14  and carrier  10  for examination by the controller  26  via cameras  132 . The arrangement  76  also features focal adjustment screws  136  whereby a focal point of the cameras  132  can be manually adjusted. 
         [0138]    The Inventor has found that AVT F-131B cameras, which are IEEE1394 SXGA C-mount cameras having a highly sensitive CMOS sensor, are suitable for the application. In addition, the LEDs  138  are red, star, 1 Watt Lumileds with a 625 nm wavelength and controlled by a Gardasoft® PP610 lighting controller to provide repeatable intensity control of the LED lighting for fiducial protection. It is to be appreciated that the lighting controller forms a part of the global control system of the laminating apparatus  16 , described below. 
         [0139]    In use, the control system  26  controls the linear stage actuator  80  ( FIG. 6 ) to move the cradle  18  with carrier  10  around under the camera arrangement  76 . This is after the table assembly actuator  84  has moved the table  21  into the apparatus  16 . The cameras  90  allow the control system to “see” when the fiducials and apertures align. 
       Bonding Apparatus 
       [0140]    The bonding apparatus  24  is shown in more detail in  FIGS. 11 to 13 . The bonding apparatus  24  is controlled by the controller  26  to provide the required pressure and heat to bond the film  14  to the carrier  10  after alignment of the fiducials and apertures. The bonding apparatus  24  includes a heated lamination head  146  actuated by actuator cylinder  154 . Also included is a conformal tape dispensing assembly consisting of a tape feed reel  88  and tape take-up reel  148  with respective reel actuators  118  and  116 . The reels  88  and  148  dispense a conformal tape  152  over the head  146  to facilitate even distribution of heat and pressure. The apparatus  24  includes an incremental tape sensor  150  to measure the amount of tape  152  dispensed over the head  146 . The Inventor has found that Fujipoly® SARCON black 850 μm tape is suitable for the application. 
         [0141]    The lamination head  146  is shown in more detail in  FIG. 13 . The head  146  generally features a plate support  160  to support an insulation sheet  162 , a heater cartridge  157  and a lamination plate  158 , as shown. The sheet  162 , cartridge  157  and plate  158  are attached to the support plate  160  via retaining screws  156 . 
         [0142]    Once the lamina film  14  has been aligned with the carrier  10 , the table actuator  84  moves the table  21  to the bonding apparatus  24 . The bonding apparatus  24  then lowers the lamination head  146  with pneumatic actuator  154  to apply heat and pressure to bond the film to the carrier  10 . Actuator  154  is a pneumatic actuator piston and cylinder arrangement in the form of an SMC compact guide cylinder to achieve the necessary pressure. 
       Alignment Mechanism 
       [0143]    The alignment mechanism, broadly indicated by reference numerals  20 ,  22 ,  24  in  FIGS. 3 and 6  (components separately described above), is responsible for aligning the film  14  fed over the platform  18  with the carrier  10 . It is to be appreciated that the controller  26  typically automates the alignment process. To this end, the alignment mechanism  22  includes the camera arrangement  76  of  FIG. 10 . The camera arrangement  76  enables the controller  26  to examine the film  14  and carrier  10  and to actuate the cradle platform  18  to align the fiducials with corresponding holes in the film. 
         [0144]      FIG. 14  shows a top diagrammatic view of the different actuators required by the lamina supply  20 , the lamination support and the bonding apparatus  24  which together constitute the alignment mechanism. The indicated actuators are typically electrical actuators under control of the controller  26 . The controller  26  is configured to control the operation of the respective actuators in response to feedback from a number of sensors, such as the camera arrangement  76 . Actuator  100  is used to control the final position of the lamination film  14  in relation to the carrier  10 . Actuators  102  and  104  are responsible for displacing the cradle platform or lamination support  18  in a plane coplanar with the representation of  FIG. 7 . The Inventor has found that the Ealing EncoderDriver™ actuator package 37-9685 is suitable for actuators  100 ,  102 , and  104 . These actuators include an integral DC motor, gearhead, micrometer precision leadscrew and magnetic encoder which provides full sub-micrometer control of said platform  18  to the controller  26 . 
         [0145]    The actuator  106  is responsible for moving the lamination film gripper  130  with the drivebelt  129 . The gripper assembly  96  picks up the lamination film from the lamina supply film reel  94  and feeds it across the platform  18 , as described above. The actuators  100 ,  102 , and  104  provide final and accurate positioning of the film  14  and carrier  10 . 
         [0146]    The actuator  108  drives a lamination tape cleaning roller  120  ( FIG. 8 ). The actuator  110  drives the lamination film feed reel  94  and actuator  114  drives a lamination liner take-up spool  122 . The actuators  116  and  118  are responsible for feed and take-up, respectively, of the conformal tape  152  across the lamination head  146  ( FIG. 11 ) of the bonding apparatus  24 . The actuator  112  is an electric cylinder and motor to move the table assembly  72  into position for bonding the lamina with the bonding apparatus  24 . The Inventor has found the Maxon® RE30 series of motors suitable for actuators  106 ,  108 ,  110 ,  114 ,  116 , and  118 . The Inventor has found the Parker® ETB32-B08P series actuator suitable for actuator  112 . 
         [0147]    Circuit diagrams of the above actuators and linear encoders are discussed in more detail below with reference to  FIGS. 23 to 38 . 
       Lamina Alignment 
       [0148]    An example of an output shown on the PC with display panel  56  is shown in more detail in  FIG. 15 . The display provides the operator with a view of the alignment process performed by the controller  26 , and generally includes a view of the carrier  10  and film  14  taken by the camera arrangement  76 , described above. Reference numeral  142  in  FIG. 15A  indicates a view displayed on the PC panel  56  while the fiducials  12  are not yet aligned, whilst reference numeral  144  in  FIG. 15B  shows a view of fiducials  12 . 2  aligned with the corresponding holes  12 . 1  in the film  14 . 
         [0149]    It is to be appreciated that the alignment process is under control of the control system  26 . However, in one embodiment of the invention, the controller  26  allows the operator to attempt manual alignment should the controller  26  be unable to align the fiducials  12 . 1  and the holes  12 . 2  successfully. In such a case, the controller  26  will provide the operator with an override control of the alignment process, typically via buttons on the touch screen display  54 , or the like. This may occur where the control system  26  is unsuccessful in detecting the fiducials. 
       Control System 
       [0150]    Referring now to  FIGS. 16 to 19 , the components of the controller or control system  26  of the laminating apparatus  16  are now discussed in further detail. It is to be appreciated that the controller  26  comprises a number of separate components and sensors in order to fulfill all the functions and tasks required from the controller  26 . In addition, the laminating apparatus  16  includes a safety system which is typically defined by means of the different sensors and operating instructions performed by the control system. 
         [0151]      FIG. 16  shows the panel  30  of  FIG. 3  in an open position so that internal components of the control system are visible. The flat panel PC  56  is shown, along with pressure sensors  60  and  62 . Also visible is a programmable logic controller (PLC) block  26 , which forms a functional element of the safety and control system. The PLC  400  is connected to the PC  56  at  402  to receive its program from the PC  56 . 
         [0152]    The PLC  26  is modular as shown in the rail mounting positions diagram  404 . The PLC  402  includes a main controller block  414 , a Controller Area Network (CAN) serial bus block  408 , a 12-bit, 4 channel analogue output block  410 , a temperature control block  412 , a 2 or 4 input module  406  and an Ethernet interface block  416 . 
         [0153]    The modular PLC block effectively represents controller  26 . As will be appreciated by a skilled person, the PLC  26  is responsible for the overall control and management of the apparatus  16 . Some of the components controlled by the PLC  26  include the cradle platform  18  with related actuators, the lamina supply  20 , the bonding apparatus  24 , the alignment mechanism  22 , and the barcode scanner  38 . 
         [0154]    The internal components visible in  FIG. 16  are generally connected by means of trunking  55 , which houses the necessary connectors, electrical wires and pneumatic lines to establish the required connection between the components. 
         [0155]    The PLC  26  typically includes a number of different modules each responsible for different aspects. For example, analog and network communication blocks may be used to interact with different pneumatic sensors and to interface the PLC  26  with the remote monitoring system. The Inventor has found the Mitsubishi® FX3U-48MR PLC suitable as controller  26 , along with a FX2N-2LC temperature control block, a FX2N-4AD analog input module, a FX2N-4DA analog output module, a FX3U-ENET Ethernet interface module, and a FX2N-32CAN controller area network serial bus block. These modules collectively represent the PLC block  26 . 
         [0156]    The controller block  26  is connected to receive inputs from the start buttons  44 . The controller block  26  is also configured to control operation of the positioning or linear stage actuator  80 , the barcode scanner  38 , the warning beacon  42 , the ultrasonic knife assembly  86  and the grippers  128 ,  130 . The controller block  26  is also configured to control operation of controllers  418 ,  420 ,  422  of the liner take up spool  122  and the reel actuators  116 ,  118 , respectively ( FIG. 38 ). 
         [0157]    Also shown is a Firewire interface card  172  to interface the PLC  26  with the camera arrangement  76 . A fan unit  174  is included to provide cooling and ventilation. The Inventor has found a Sunon 24V DC brushless fan with Papst filter assembly to be suitable for this purpose. A power supply  176  is also included to provide power to the ionizer bar  98  of the lamina supply  20 , along with the LED light controller  170 , described above. Solenoid valves  166  are shown to control pneumatic elements of the apparatus, specifically the bonding apparatus and a knife assembly, and a network switch  168  to interconnect the PLC FX3U-ENET Ethernet interface module, the flat panel PC  56  and an external RJ45 connector  202  ( FIG. 18 ). Also shown are fuses  164  to provide protection to electrical circuitry of the controller  26 . 
         [0158]      FIG. 17  shows the rear equipment enclosure  34  in an open position with internal components visible. The enclosure  34  also includes trunking  33  through which the necessary electrical and pneumatic connections between components can be established. Motion axis controllers  178  provide an interface between the axis actuators described above with reference to  FIG. 14  and the PLC  26 . Relays  200  are used on the barcode scanner  38  and the ultrasonic knife assembly  86 , described below. Fuses  198  provide additional electrical protection to the electrical components, along with circuit breakers  196 , which are Hager AD 810T residual current circuit breakers. 
         [0159]    Respective components of the apparatus  16  are supplied with electricity through three power supply units  194 . The first unit is a Cosel PBA300F-24 24V DC power supply unit to supply appropriate voltage levels to some of the axis actuators, with a second PBA50F-12 power supply also providing power to some of the axis actuators. A PBA50F-9 power supply unit provides power to the barcode scanner  38 , the PC unit  56  and PLC  26 , and the LEDs. In this manner, all electrical components are supplied with required voltage levels. Transformers  192  are used to supply the ultrasonic knife  86  with AC current. Transformer  186  is used to supply AC power to some of the axis actuators. A capacitor and bridge rectifier circuit  190  provides filtering and rectification of an input AC supply. Motor contactors  182  are used to control starting of the axis actuators, and circuit breakers  184  provide electrical protection for the contactors  182 . 
         [0160]      FIG. 18  shows an internal view of the service panel  36 . The RJ45 connector  202  can be seen, with which the PLC  26  is arranged in contact with the remote monitoring system. Also shown is an AC mains isolation switch  204  for safety purposes, and a main air isolation valve for the pneumatic components of the apparatus  16 . A mist separator  208  is used to filter particles from an incoming air supply of the pneumatic components.  FIG. 19  shows an external view of the panel  36 , showing an incoming AC mains connector  210 , and an incoming air supply connector  212 . 
         [0161]    As discussed above, the apparatus  16  includes a safety system to ensure safe operation thereof and to minimize damage to the carrier  10  and the apparatus  16 , as well as to prevent harm to the operator. As described above, the safety system is typically implemented via the controller  26 . 
         [0162]    As such, the controller  26  is linked to a number of regulators, as described above, which include sensors for monitoring air pressure. An undesired pressure typically indicates an undesired operational status of the apparatus  16 , and the controller  26  can deactivate the tester and its components to prevent damage and/or harm. In addition, the controller  26  is also linked to a number of position sensors to sense positions of movable mechanisms, such as the cradle platform  18 , the lamina supply, the alignment mechanism  22 , the bonding apparatus  24 , etc. A person skilled in the art will appreciate that the controller  26  may be configured to monitor any feature relating to the operational status of the apparatus  16 . 
       Circuit Diagrams 
       [0163]      FIGS. 23 to 38  show circuit diagrams of interconnections between the electrical components described above. It is to be appreciated that the circuit diagrams are described in overview with only some of the connections indicated. The circuit diagrams are meant to assist the skilled person in interpreting the interconnections between the components, and not to provide an exhaustive circuit description. In the circuit diagrams, like reference numerals indicate like connections unless otherwise indicated. 
         [0164]      FIG. 23  shows a safety system which forms part of the control system of the apparatus  16 . Light curtain sensors  40  are shown, along with a light curtain controller  480  and safety relay  180 . Limit switches  490  of the table  21  are indicated, as well as emergency stop buttons  492 . The connections from the respective motion axis controllers (collectively indicated by  178  in  FIG. 17 )  438 ,  440 ,  442 ,  444 ,  446 , and  448  are also shown. These connections are indicated when the respective motion axis controllers are described below. The safety system indicated includes a number of mute connections to the PLC  400  to halt all activity should the safety circuitry be activated. Main pneumatic system venting valves  494  are also indicated. These valves  494  vent air pressure when the safety circuitry is active. 
         [0165]    With reference to  FIG. 24 , a modular PLC controller block  26  is shown. As mentioned above, the PLC block  26  includes the Mitsubishi® FX3U-48MR PLC  400  along with the FX2N-2LC temperature control block  406 , a FX2N-4AD analog input module  408 , a FX2N-4DA analog output module  404 , a FX3U-ENET Ethernet interface module  410 , and a FX2N-32CAN controller area network serial bus block  402 . 
         [0166]    PLC  400  includes power connection  424 , along with a plurality of controlling connections (collectively indicated by reference numeral  496 ) for controlling the respective pneumatic components.  FIG. 25  shows the respective pneumatic components controlled by the PLC  400  via the controlling connections  496 . Connection  422  indicates a common earth for the control system. The PLC  400  is connected to the PC  56  at connection  412 . 
         [0167]    The FX2N-4DA analog output module  404  has connection  416  to motion axis controller  474  ( FIG. 35 ) of drive  114  actuating the take-up spool  122 , and connections  418  and  420  to motion axis controller  476  ( FIG. 36) and 478  ( FIG. 37 ) of reel actuators  118  and  116  of the conformal tape dispensing assembly ( FIG. 12 ). The FX2N-32CAN controller area network serial bus block  402  forms the interface between the PLC  400  and the motion axis controllers  178  ( FIG. 17 ) via serial connection  414 . The motion axis controllers are collectively indicated by reference numeral  178  in  FIG. 17 . These controllers are shown individually in  FIGS. 28 to 37 . These controllers are respectively indicated by  436 ,  462 ,  464 ,  466 ,  468 ,  470 ,  472 ,  474 ,  476  and  478 . All these controllers are serially connected to the PLC  400  via serial bus block  402 . 
         [0168]      FIG. 26  shows an overview of a network arrangement formed between the PC  56 , cameras  90 , Ethernet switch  168  and Ethernet module  410  of the PLC block  26 . PC  56  is connected to the relevant power supplies, described above, at connection  426 . Barcode scanner  38  is also connected to PC  56 . 
         [0169]      FIG. 27  shows a power circuit of the apparatus  16 . Indicated are power connection  434  to the relevant power supply described above, ultrasonic knife transformers  192  and ionizer power supply  176 . Power connection  432  to motion axis controller  472  ( FIG. 34 ) is also shown. 
         [0170]      FIG. 28  shows motion axis controller  436  responsible for drive  100 , as indicated. Motion axis controller  436  includes serial connection  414  to serial bus block  402  of the PLC block  26 , serial connection to the next motion axis controller  462  ( FIG. 29 ), and connection  438  to the safety circuitry of  FIG. 23 . Also shown is power connection  482  to a power supply of the apparatus  16 . 
         [0171]      FIG. 29  shows motion axis controller  462  responsible for drive  102 , as indicated. Motion axis controller  462  includes serial connection  450  to motion axis controller  436  ( FIG. 28 ), serial connection  452  to the next motion axis controller  464  ( FIG. 30 ), and connection  440  to the safety circuitry of  FIG. 23 . Also shown is power connection  484  to a power supply of the apparatus  16 . 
         [0172]      FIG. 30  shows motion axis controller  464  responsible for drive  104 , as indicated. Motion axis controller  464  includes serial connection  452  to motion axis controller  462  ( FIG. 29 ), serial connection  454  to the next motion axis controller  466  ( FIG. 31 ), and connection  442  to the safety circuitry of  FIG. 23 . Also shown is power connection  486  to a power supply of the apparatus  16 . 
         [0173]      FIG. 31  shows motion axis controller  466  responsible for drive  106 , as indicated. Motion axis controller  466  includes serial connection  454  to motion axis controller  464  ( FIG. 30 ), serial connection  456  to the next motion axis controller  468  ( FIG. 32 ), and connection  457  to the safety circuitry of  FIG. 23 . Also shown is power connection  459  connected to safety circuitry shown in  FIG. 23 . 
         [0174]      FIG. 32  shows motion axis controller  468  responsible for drive  108 , as indicated. Motion axis controller  468  includes serial connection  456  to motion axis controller  466  ( FIG. 31 ), serial connection  458  to the next motion axis controller  470  ( FIG. 33 ), and connection  444  to the safety circuitry of  FIG. 23 . Also shown is power connection  488  to a power supply of the apparatus  16 . 
         [0175]      FIG. 33  shows motion axis controller  470  responsible for drive  110 , as indicated. Motion axis controller  470  includes serial connection  458  to motion axis controller  468  ( FIG. 32 ), serial connection  460  to the next motion axis controller  472  ( FIG. 34 ), and connection  446  to the safety circuitry of  FIG. 23 . Also shown is power connection  490  to a power supply of the apparatus  16 . 
         [0176]      FIG. 34  shows motion axis controller  472  responsible for drive  112 , as indicated. Motion axis controller  472  includes serial connections  428  and  430  back to the PC  56  of  FIG. 26 . Also shown is connection  448  to the safety circuitry of  FIG. 23 , and power connection  432  to a power supply of the apparatus  16 . The motion axis controller  472  of  FIG. 34  has a direct feedback connection to PC  56  via a suitable network port  498 . Motion axis controller  472  controls actuator  112  responsible for displacing table assembly  21  to move cradle platform  18  from the lamina supply  20  to the alignment mechanism  22  to the bonding apparatus  24 . As the alignment mechanism  22  relies on the camera arrangement  76 , which is directly connected to PC  56 , a direct feedback connection  430  to the PC  56  is necessary to allow the PC to sense when the table assembly is in position. A serial connection  428  also connects the motion axis controller  472  to PC  56 , as shown. 
         [0177]      FIG. 38  shows an embodiment of an incremental conformal tape sensor connected to PLC  400  via the controlling connections  496 . 
       Ultrasonic Knife Assembly 
       [0178]    The ultrasonic knife assembly  86  is shown in more detail in  FIG. 20 . The assembly  86  is used by the controller  26  to cut excess lamina film from the carrier  10  after bonding. The assembly  86  includes a blade  216 , blade securing screw  214 , blade guard  220  with Teflon™ pad  218  and blade guard securing screws  222 . The Inventor has found the Alex Corporation KW-430C portable cutters suitable for this application. These cutters are designed to cut the lamina without leaving a residue. 
         [0179]    The knife assembly  86  is also controlled by the controller  26 . Once the bonding apparatus  24  has successfully bonded the aligned lamina with the carrier, the controller  26  activates the knife assembly to cut the excess lamina from the carrier  10 . 
       Lamination Method 
       [0180]    A block diagram of a process or method outline is shown in  FIG. 21 . It is to be appreciated that reference to a reference numeral representing a particular method step refers to a respective block indicated by such reference numeral in the accompanying drawings. As such, the method included in the invention is not limited or constrained to particular method steps referred to in this manner. A skilled person will understand that further methods are possible under this invention which might exclude some of these steps or include additional steps. 
         [0181]    The steps shown are typically performed under one embodiment of the invention, with other embodiments having different steps. In preparation of the bonding process, the operator must make sure that any consumables are present, such as the lamina film. If not, the lamina supply  20  must be refilled. This is done by retrieving a new film reel from a storage cabinet, shown at block  224 , scanning a barcode of the new film reel with the barcode scanner  38  (block  226 ), and loading the reel into the lamina supply (block  234 ). 
         [0182]    The scanning of the barcode of the replacement film reel (block  226 ) results in communication of this scanned barcode to the remote monitoring system, typically for quality control and assurances purposes. Such a quality control process is shown at blocks  228 ,  230  and  232  where the barcode is uploaded to the remote monitoring system, compared with known good barcodes, and a result is shown on the display  56 . The results so displayed are typically whether or not the barcode scan was successful. 
         [0183]    The operator must also load the carrier  10  into the cradle platform  18 . The operator removes the carrier  10  from storage (block  238 ) similarly scans the carrier&#39;s barcode (block  240 ) which is also checked by the remote monitoring system (blocks  242 ,  230  and  232 ), and placed on the cradle platform (block  244 ). Once the controller  26  has verified that the carrier  10  is in place and the lamina supply  20  has film  14 , the controller  26  proceeds with automatically aligning the carrier fiducials with the holes in the film. 
         [0184]    Block  236  indicates a step of gripping the film with the film gripper  128  and  130  ( FIG. 9 ) and feeding the film over the carrier  10  on the platform  18 . The controller  26  then moves the carrier in line with the film fed over the platform  18  by means of the axis actuators, described above with reference to  FIG. 14 , indicated by block  246 . 
         [0185]    The controller  26  then uses the camera arrangement  76  to locate the fiducials on the carrier and the holes in the film  14 , shown at block  248 . Once the fiducials  12  and holes are aligned, the carrier  10  and film is moved under the bonding apparatus, as indicated by block  250 . The binding apparatus  24  then applies heat and pressure to bind the film to the carrier  10 , as at block  252 . 
         [0186]    Once the film has been bonded to the carrier, any excess film is removed by the ultrasonic cutter  86 , indicated at block  254 . The cradle platform  18  is then moved out from under the bonding apparatus  24  (block  256 ) to an unloading position, so that the operator can remove the bonded carrier  10  at block  258 . The operator also removes waste film removed by the cutter  86  from the apparatus  16  at block  260 . The removed carrier generally appears as shown in  FIG. 2 . 
         [0187]      FIG. 22  shows a similar functional block diagram for typical steps performed by the apparatus  16  in one embodiment of the invention. The apparatus initializes (block  280 ) with the controller  26  performing self-tests and checks whether or not all the electrical and pneumatic components are functioning correctly. A barcode of the carrier is then scanned, as described above (block  282 ). As indicated at block  284 , the barcode scanner  38  keeps scanning until the barcode is successfully scanned. 
         [0188]    The operator then proceeds to load the carrier  10  into the cradle platform  18  (block  286 ). Blocks  288  and  290  show steps for scanning a barcode of the lamina reel  94 , so that the remote monitoring system can register which carriers have been laminated with which lamina. This facilitates quality and assurance checks. 
         [0189]    If the carrier is loaded and all barcodes have been scanned and sent to the remote monitoring system, the start buttons are activated by the controller  26 , so that the operator can press the buttons  44 . 1  and  44 . 2  to instruct the apparatus  16  to laminate the lamina film to the loaded carrier. When ready, the operator presses the start buttons  44  (block  292 ). 
         [0190]    The film gripper assembly  96  then feeds the lamina film from reel  94  to film gripper  130 , as described above (block  294 ). The operator then pushes the start button again (block  296 ), so that the film gripper  130  pulls the lamina film across the cradle  18  (block  298 ), described above. The controller  26  then operates linear stage actuator  80  to move the carrier in cradle  18  to below the film drawn between film grippers  128  and  130  (block  300 ). 
         [0191]    The controller  26  then uses the camera arrangement  76  to locate the fiducials and apertures of the lamina film and carrier, as described with reference to  FIG. 15  above (blocks  302  and  304 ). Once the fiducials and apertures have been aligned, the table assembly actuator  84 , under control of the controller  26 , moves the table  21  with the cradle  18  and lamina to the bonding apparatus  24  (block  306 ). 
         [0192]    The controller  26  lowers the laminating head  146  (block  308 ) to bond the aligned lamina to the carrier  10  with heat and pressure (block  310 ). After a predetermined time, the controller  26  raises the laminating head  146 , as at block  312 , via actuator  154 . 
         [0193]    After bonding, the controller  26  actuates table assembly actuator  84  to move table  21  into a cutting position where the ultrasonic knife assembly  86  can cut the lamina remaining from the carrier (block  314 ). Once the cradle  18  with carrier is in the cutting position, the controller  26  lowers the knife assembly  86  (block  316 ) and activates the cutters to cut the remaining lamina (block  318 ). The controller  26  can move the cradle  18 , by means of actuator  84 , to expose the cutters to the lamina so that accurate removal of the lamina is facilitated (block  320 ). 
         [0194]    After the excess lamina has been removed from the carrier, the controller raises the knife assembly (block  322 ) and moves the table  21  and cradle  18  out of the apparatus to enable unloading of the bonded carrier (block  324 ). Once the cradle  18  with the carrier is in the loading position, the controller  26  releases the film grippers  128  and  130  (block  326 ) so that any remaining lamina film can be rewound onto reel  94  via the lamina supply mechanism  20 , as described above (block  328 ). 
         [0195]    The controller  26  then releases the carrier from the cradle  18  so that the operator can remove the carrier from nest formation  235  and remove any residual film from the apparatus (blocks  330  and  332 ). 
         [0000]    It is to be appreciated that the invention also extends to include a software product for execution by the controller or PLC  26 , as described above. The software product enables the PLC  26  to perform the functions and relevant method steps described above. The invention inherently includes a computer readable medium, such as a magnetic or optical disc, incorporating such a software product.