Field of invention

The invention relates to a packing apparatus for automatically packing component carriers. Furthermore, the invention relates to a method of automatically packing component carriers.

Art Background

A component carrier, such as a printed circuit board (PCB) or a substrate, mechanically supports and electrically connects active and passive electronic components. Electronic components are mounted on the component carrier and are interconnected to form a working circuit or electronic assembly. In the manufacturing process of component carriers, the component carriers are formed in one common component carrier structure. Hence, the component carrier structure comprises a plurality of component carrier segments. The component carrier my form a plate like element. After checking the function and quality of each component carrier, the component carrier is stacked to a bundle of component carriers and, for the further transportation to a customer, the bundle of component carriers is packed together. The steps of quality control and of packing of the component carriers are performed in separated working processes and are conducted mainly by human inspectors or packing workers.

Hence, there may be a need for improving the testing and packaging procedure of component carriers.

Summary of the Invention

This need may be met by a packing apparatus and a method for automatically packing component carriers. According to a first aspect, a packing apparatus for automatically packing component carriers is presented. The packing apparatus comprises a gating arrangement configured for allowing only component carriers to proceed with packing which meet at least one predefined gating criterion.

Furthermore, the packing apparatus comprises a tracing arrangement configured for tracing the component carriers during processing by the packing apparatus and a packing unit for packing the traced component carriers, which meet the at least one, preferably all, predefined gating criterion(s), to a component carrier pack. This will enhance the possibility that (merely) component carrier which fulfil the gating criterion(s) will be further packed and transported to the packing unit and finally to the consumer, respectively.

According to a further aspect, a method of automatically packing component carriers in a packing apparatus is presented. The method comprises allowing only component carriers to proceed with packing which meet at least one predefined gating criterion, tracing the component carriers during processing by the packing apparatus, and packing the traced component carriers meeting the at least one predefined gating criterion.

In the context of the present application, the term "component carrier" may particularly denote any support structure which is capable of accommodating one or more components thereon and/or therein for providing mechanical support and/or electrical connectivity. In other words, a component carrier may be configured as a mechanical and/or electronic carrier for components. In particular, a component carrier may be one of a printed circuit board, an organic interposer, and an IC (integrated circuit) substrate. A component carrier may also be a hybrid board combining different ones of the above-mentioned types of component carriers. In the component carrier comprises a plurality of through holes may be drilled by laser or mechanical drilling. The through holes may be later on filled with conductive material (e.g. by plating) for providing electrical connections of the component carrier. The component carrier comprises a plurality of component carrier segments that are fixed together during the manufacturing procedure. The component carrier comprises one of the group consisting of a panel, a quarter panel, and an array of component carrier segments. On the side of the manufacturer or on the side of the customers, the component carrier segments of the component carrier structure may be singularized in order to integrate the single component carrier segment in the respective product.

The gating arrangement comprises for example several sensors, such as an optical sensor, e.g. a camera, which analyzes if the component carriers and/or a respective bundle of component carriers or also respective trays carrying the component carriers comply with certain gating criterions, such as a warpage of a component carrier or a tray as described below. Furthermore, a laser sensor may be applied. Hence, a laser beam of the laser sensor may be used to measure a specific height and warpage, respectively, of the component carriers or of a respective tray carrying the component carrier, in order to check, if a warpage is out of the predefines specification.

The tray material may comprise metals, alloys, polymer (composites), glass, ceramics, wood and/or mixtures thereof. The tray may comprise at least one accommodation space (e.g. a recess) for accommodating a respective component carrier. The accommodation spaces (recesses) may comprise different sized for accommodating component carriers with different dimensions on a tray.

If the respective component carrier or the respective tray fulfills the respective gating criterion, the gating arrangement releases the respective component carrier to proceed with packing which meet at least one predefined gating criterion. Along the complete packaging process, between several packaging steps, a gating of the gating arrangement takes place, so that along the complete packaging process quality and hence the gating criterion can be verified. In case of not fulfilling a specific gating criterion the component carrier will be considered as not further processable (scrap part) and will be sorted out by the packing apparatus or any other manipulator configured for gripping and sorting out the respective component carrier or tray. In order to trace the component carriers during the packaging process, the packing apparatus comprises the tracing arrangement configured for tracing the component carriers and/or the trays carrying the respective component carriers during processing by the packing apparatus. Hence, the respective component carrier and/or tray may comprise respective identifiers, that can be recorded by the tracing arrangement, such that the tracing arrangement can verify the component carrier and/or tray. The tracing arrangement may comprise a plurality of tracing sensors, such as cameras, that can be arranged at several stations throughout the packaging apparatus, so that along the complete packaging process, the respective component carriers to be packed can be traced.

If the component carrier fulfills the gating criterion, finally a certain stack of component carriers can be packed to a bundle and to a carrier pack, respectively for transportation.

According to the present invention, in one common packing arrangement, a quality (gating) control as well as a packaging process for component carriers is summarized. Hence, for example automatic manipulator devices, such as robot or conveying belts, transport the component carriers between the stages of the packing arrangement. No human interaction may be necessary in regular operation. Hence, a more efficient packaging process for component carriers can be provided.

According to a further exemplary embodiment, the gating arrangement is configured for allowing only component carriers to proceed with packing which meet the gating criterion that warpage of a tray accommodating component carriers is below a predefined warpage threshold value. Accordingly, the method comprises allowing only component carriers to proceed with packing which meet the gating criterion that warpage of a tray accommodating component carriers is below a predefined warpage threshold value. Furthermore, in a further exemplary embodiment, the gating arrangement may also be configured for allowing only component carriers to proceed with packing which meet the gating criterion that a surface damage of the tray accommodating component carriers or of the component carriers itself is not detected. Hence, due to the check if the respective component carriers fulfill a respective gating criterion, a higher quality may be reached in a component carrier pack. Specifically, the amount of defect component carriers packed and supplied to the customer may be reduced.

Usually, the component carriers are arranged for transportation in trays which form a flat stable structure for carrying the carriers. The trays form a carrying frame forming a support surface onto which the component carriers can be attached. The risk of damage during transportation is reduced when the component carriers are transported on a tray. For transportation, a plurality of trays each carrying one or a plurality of component carriers may be stacked on top of each other for forming the carrier pack (i.e. a bundle of component carriers fixed by packing structures). However, if the trays are deformed and thus comprise a certain warpage, the support surface of the trays and hence also the component carriers arranged onto the support surface are prone to warpage as well.

Hence, after a certain amount of warpage, the trays can be used for carrying component carriers. However, if the warpage of the trays exceed a certain warpage threshold value, the respective trays are taken out of the packing process. For example, the gating apparatus comprises a first warpage detection section, wherein the warpage of each tray is checked before entering the packing process. Additionally, after several stations of the packing process, such as cleaning, flipping and stacking trays, a further second warpage detection section is arranged, wherein the second warpage detection section is configured for detecting the warpage of several trays stacked together and which need to be checked. There may be a need therefore, because during the single packaging steps, the trays may deform such that also further warpage detection may be necessary.

Specifically, after each processing step there may be the possibility to provide a gating unit (e.g. a sensor for detecting warpage) of the gating arrangement to check a respective gating criterion. Thereby it is possible e.g. to document every single process step for tracing the entire manufacturing process. For example, at each process step, the warpage of the tray and/or the component carriers can be measured. Thereby it becomes apparent, if a critical warpage as a gating criterion is achieved such that the respective tray or component carrier can be taken out of the production line.

The gating criterion regarding warpage may be determined by optical sensors, for example by cameras. For example, the cameras may detect, if corner regions of a respective tray have different heights. If the heights of the corners differ to each other, this may be a hint that the tray is deformed. The warpage criterion may define for example a height difference between corner sections of the tray. If the difference between the heights of the corners section of the tray exceed a predefined threshold value, the respective tray is taken out of the packing process.

The gating criterion regarding warpage may also be determined by detecting a height of the tray and/or the component carrier. For example, an allowable standard tray height may be 12,19 mm. However, if a warpage of a part of the tray, for example a corner section of the tray, leads to a height between the bottom of the tray and the highest point (i.e. the corner) of the tray that exceeds an overall height of more than e.g. 12.95 mm (as a gating criterion), the tray may be taken out of the production line. The value for the warpage gating criterion may also be defined in percent. If a regular flat tray without any warpage comprises a certain height between a top surface and the bottom surface, a difference to the height of more than 5% or of more than 10% may be set as a predefined threshold value for the warpage. Hence, if thickness or distance between an uppermost part of the tray and a lower most part of the tray exceeds more than 105% or 110% of the thickness of the tray without any warpage, the respective tray may be taken out of production line.

Furthermore, also a laser sensor as a warpage sensor may be used, wherein a light beam is directed, specifically in an 90° angle (perpendicular), with respect to the surface of a component carrier or tray to be measured. The surface of the respective tray and/or the component carrier reflects the light beam. If the reflected light beam does not hit the laser sensor again, there must be a certain warpage. Furthermore, as a warpage sensor, a physical jig gate may be used. If the tray and/or the component carriers fit under the jig, the warpage gating criterion is met.

According to a further exemplary embodiment, the gating arrangement is configured for allowing only component carriers to proceed with packing which meet the gating criterion that a position of component carriers accommodated in a tray meet a predefined position criterion. Accordingly, the method may comprise allowing only component carriers to proceed with packing which meet the gating criterion that a position of component carriers accommodated in a tray meet a predefined position criterion.

The position of the component carrier on the respective tray has to be determined, such that for example after a stacking of the trays, misaligned component carriers and the tray will not be damaged. The predefined position criterion may define an allowable offset of the component carrier with respect to an ideal component carrier position in the tray. For example, if the component carrier on the tray has an offset with respect to the ideal component carrier position, the tray is allowed to proceed for further packaging, wherein a component carrier and the tray having an offset of more than an allowed threshold value has to be sorted out from a further packaging. For example, a distance between a component carrier edge to a tray edge may be predetermined (e.g. 100%). The allowed offset for a deviation may be set as a position gating criterion. If the offset is more than ± 10%, in particular more than ±5%, more in particular more than ±2%, a wrong position of the component carrier on the tray is detected and the component carrier or the whole tray is sorted out before being packed. For example, if a distance between the component carrier edge to a tray edge is fixed for example 100mm and a deviation may be set as a position gating criterion to ±2mm, then if the distance is out of 98~102mm a wrong position of the component carrier is detected.

According to a further exemplary embodiment, the gating arrangement comprises a camera device to take a picture of the component carriers in the tray for evaluating if the position complies with the predefined position criterion. Accordingly, in an exemplary embodiment the method comprises taking a picture of the component carriers in the tray for evaluating if the position complies with the predefined position criterion. The gating arrangement determines for example the position of the corners of the component carrier and/or the edges of the component carrier on the tray. Additionally, the tray may comprise identification markers. The gating arrangement may determine the distance between respective edges or corners of the component carrier to the identification markers, such that from the respective pictures the position of the component carrier on the tray may be determined. Furthermore, the gating arrangement may determine the distance between adjacent component carrier on a tray. If the distance is e.g. not the same or almost equal, the gating arrangement may recognize that there must be a misalignment of the component carriers. Specifically, the gating arrangement comprises a plurality of camera devices throughout the packing procedure for determining plurality of stations of the packing procedure the position of the component carrier on the tray. For example, as described further detail below, the component carriers and the trays may be flipped in the flipping station. Hence, it may be necessary to check after the flipping of the tray, if the component carrier on the tray still complies with the predefined position criterion. Hence, by checking and fulfilling the position criterion, a correct alignment of the component carrier in e.g. the accommodation recesses of the tray can be provided which leads to a quality enhancement.

According to a further exemplary embodiment, the gating arrangement is configured for allowing only component carriers to proceed with packing which meet the gating criterion that an overlap of component carriers accommodated in a tray beyond the tray meet a predefined overlap criterion. Accordingly, the method may comprise allowing only component carriers to proceed with packing which meet the gating criterion that an overlap of component carriers accommodated in a tray beyond the tray meet a predefined overlap criterion.

Hence, after the component carriers and the respective trays are stacked above each other, it has to be confirmed, that no lateral misalignment between the trays of component carriers exists. Hence, the position criterion determines that a threshold value for a respective offset between the trays carrying the component carriers is fulfilled. A higher stability of the stacked trays can be provided.

According to a further exemplary embodiment, the gating arrangement comprises a camera device to take a picture of the component carriers in the tray for evaluating if the position complies with the predefined position criterion and to check the amount of component carriers stacked above each other and form a bundle of component carriers. The camera device is configured for taking a top picture of the top of the bundle and a bottom picture of the bundle, wherein the gating arrangement is configured for comparing the top picture and the bottom picture for checking the predefined position criterion. Accordingly, the method comprises taking a picture of the component carriers in the tray for evaluating if the position complies with the predefined position criterion and to check the amount of component carriers stacked above each other and form a bundle of component carriers. The step of taking a picture comprises taking a top picture of the top of the bundle and taking a bottom picture of the bundle, and comparing the top picture and the bottom picture for checking the predefined position criterion. In particular, this step may be performed when a further tray or layer was added to the tray-stack. Furthermore, based on the picture taken by the camera device, the tray quantity can be determined. If a threshold of a number of trays is reached, the stack of trays may proceed to the packing unit.

For example, the camera device comprises a camera element arranged above the stack of component carriers and the further camera element arranged below the stack of component carriers. Hence, respective top and bottom pictures can be taken. Specifically, two steps for checking the overlap criterion may be accomplished. First, at the first station, first station a height of the trays is checked if for example more component carriers are positioned in one carrier of tray. Next, the top picture and the bottom picture is compared, and if the picture of top and bottom pictures show the same contours of the tray, it means the two trays are stacked with a correct overlap. Hence, misalignment of the trays in a stack may be prevented, so that the stack provides a higher reliability. According to a further exemplary embodiment, the gating arrangement is configured for allowing only component carriers to proceed with packing which meet the gating criterion that a quality property of a bundle of trays accommodating component carriers meets a predefined bundle quality criterion. Accordingly, the method may comprise allowing only component carriers to proceed with packing which meet the gating criterion that a quality property of a bundle of trays accommodating component carriers meets a predefined bundle quality criterion. For example, the gating arrangement may be determined, if the trays and the component carriers in the bundle are exposed to stress or load which can damage the respective component carriers. Hence, a higher quality of the component carriers in the bundle can be achieved.

According to a further exemplary embodiment, the gating arrangement is configured for allowing only component carriers to proceed with packing which meet the gating criterion that an electronic discharge measurement of a tray accommodating component carriers meets a predefined electronic discharge threshold value. Hence, during a packing stage, the electrostatic charge may be measured as a gating criterion. The tray and/or the component carriers may be grounded by an electrical path to the ground in a packing stage. If the electronic discharge measurement measures e.g. an electric current in an electrical path to the ground exceeding the threshold value, the gating criterion has failed. The respective tracing information of the tray or component carrier are captured by the tracing arrangement. As described below, the tray and/or the component carriers failing the electronic discharge as a gating criterion can be sorted out by a sorting unit. Hence, the risk of defect component carriers in a component carrier pack caused by electronic discharge (ESD) may be reduced.

According to a further exemplary embodiment, the gating arrangement comprises a sorting unit, which is configured for sorting out component carriers that do not meet the at least one predefined gating criterion. For example, the tray may comprise a plurality of accommodation sections for accommodating the respective component carrier. For example, if a gating criterion, such as surface damage, warpage or functional damages, of the component carrier is not met, a respective manipulator, such as a robot arm, may remove the defect component carrier from the accommodation section of the tray. Hence, amount of defect component carriers in the tray may be minimized.

According to a further exemplary embodiment, the sorting unit is configured for sorting out a component carrier from a tray accommodating component carriers. The sorting unit is in particular further configured to fill the places for carrying component carriers in the tray with component carriers meeting the at least one predefined gating criterion. Hence, the above-described manipulator may pick up component carriers meeting the predefined gating criterion from a respective storage and placed the respective component carriers in the accommodation sections. Hence, all accommodation sections for the component carriers and the tray may be filled by a respective component carriers meeting the gating criterion. Alternatively, the position in the tray may remain empty.

The tracing arrangement is configured for tracing the step of removing a component carrier removed from the tray and in particular for tracing the step of filling empty accommodation section is by a component carrier meeting the gating criterion. Hence, the tracing arrangement comprises information about the component carriers arranged in the respective tray and furthermore, tracing arrangement may comprise the pattern of accommodation section is in a tray which are occupied by a component carrier meeting the gating criterion, by a component carrier failing the gating criterion and/or the respective pattern of accommodation section which is not occupied by any component carrier. Hence, exact information about the component carriers arranged on the tray can be retrieved by the tracing arrangement.

The accommodation section may comprise an accommodation recess in which a respective component carrier may be placed. Preferably in one accommodation recess of the tray, one component carrier is placed. Alternatively a plurality of component carriers may be placed in the same accommodation recess of the tray. According to a further exemplary embodiment, the gating arrangement comprises a force sensor which is configured for detecting a force load of the bundle of trays, wherein the force load of the bundle of trays is indicative for the quality property of the bundle of trays. Accordingly, the method may comprise detecting a force load of the bundle of trays, wherein the force load of the bundle of trays is indicative for the quality property of the bundle of trays. In particular, a force sensor is configured for detecting force of the bundle after bundling. For example, the force may be the pressure force or the weight force acting between two adjacent stacked trays. For example, if too much weight acts on a lowermost tray in the bundle, damage may appear. If a respective weight force exceeds a predefined threshold value, the quality property criterion is not fulfilled and the bundle is not proceeded in the next packing step. Hence, also tray warpage caused by too heavy bundle force may be prevented.

Furthermore, the force sensor may measure the force applied to the bundle of trays by a packing structure, e.g. by a strip wrapped around the bundle of trays. If the tension of the strip would be too high, damage to the tray and the component carriers, respectively may be caused.

According to a further exemplary embodiment, the gating arrangement is configured for allowing only component carriers to proceed with packing which meet the gating criterion that a height of a bundle of trays accommodating component carriers meets a predefined height criterion. Accordingly, the method may comprise allowing only component carriers to proceed with packing which meet the gating criterion that a height of a bundle of trays accommodating component carriers meets a predefined height criterion. For example, the height may be measured by a position sensor and a camera, respectively. If the height of a bundle of trays exceeds a predefined height limit is the height criterion, the respective bundle is sorted out and stopped from the further packing procedures. If the bundle of trays is higher than the predefined height limit, this can be a hint for a misalignment or a damage of a respective tray. According to a further exemplary embodiment, the tracing arrangement is configured for tracing the component carriers by detecting component carrier identifier structures on the component carriers and for storing corresponding component carrier tracing information.

Each component carrier may comprise a specific identifier structure, such as a serial number or a specific laser mark (e.g. an RFID-Tag or 2D. ID (i.e. a QR- Code etc.), so that a unique identification (unique ID) for each component carrier is given and stored in a database. Hence, the tracing arrangement may comprise tracing elements, such as cameras, at several positions in the packing process, so that upon detecting the identifier, it can be verified which component carrier is on which position in the packing process. If a defect of a component carrier is determined, the defect component carrier can be registered in the database storing the unique identification tags for each component carrier. Furthermore, the determined defect of a component carrier may cause an action for highlighting the defect component carrier. For example, a visual mark, e.g. caused by scrapping of the component carrier, can be provided or it can be highlighted that the final bundle of stacked component carrier trays comprise defect component carriers in certain trays on marked accommodation sections of the tray. The tracing arrangement provides the location and information of the defect component carrier. Hence, a quick and precise traceability can be provided for minimizing costs to find defect component carriers.

According to a further exemplary embodiment, the tracing arrangement is configured for tracing the component carriers by detecting tray identifier structures on trays accommodating the component carriers and for storing corresponding tray tracing information.

Similar to the component carriers, each tray may also comprise a specific identifier structure, such as a serial number or a specific laser mark (e.g. an RFID-Tag or 2D. ID (i.e. a QR-Code etc.), so that a unique identification (unique ID) for each tray is given and stored in a database. Hence, the tracing arrangement may comprise tracing elements, such as cameras, at several positions in the packing process, so that upon detecting the identifier of the tray and/or the component carriers on the tray, it can be verified which tray/ component carriers is on which position in the packing process. If a defect of a tray is determined, the defect tray can be registered in the database storing the unique identification tags for each tray. The tracing arrangement provides the location and information of the component carrier. As described above, the determined defect of a tray may cause an action for highlighting the defect tray. For example, a visual mark, e.g. caused by scrapping of the tray, can be provided or it can be highlighted that the final bundle of stacked component carrier trays comprise defect component carriers in certain trays on marked accommodation sections of the tray.

According to a further exemplary embodiment, the tracing arrangement is configured for tracing the component carriers by detecting packing identifier structures on a packing structure enclosing the component carriers and for storing corresponding packing structure tracing information.

The packing structure may be a carton box or a (plastic) foil enveloping the bundle of component carriers. The packing structure may also be a pallet, onto which the bundle is arranged. Similar to the component carriers, each packing structure may also comprise a specific packing identifier structure, such as a serial number or a specific laser mark (e.g. an RFID-Tag or 2D. ID (i.e. a QR- Code etc.), so that a unique identification (unique ID) for each packing structure is given and stored in a database.

According to a further exemplary embodiment, the packing apparatus comprises a cleaning arrangement configured for cleaning the component carriers before packing. The cleaning arrangement may comprise for example high-pressure nozzles such that by high-pressure residues or other particles can be blown away from the component carriers for cleaning purposes. Alternatively, the cleaning arrangement may comprise a sucking tool (like a vacuum cleaner) to collect the dust located on the component carriers and the trays, respectively. Throughout the whole packing process, plurality of cleaning devices, specifically high- pressure cleaning devices, of the cleaning arrangement are provided. Hence, after some or all process steps of the packing procedure, an intermediate cleaning of the component carriers by applying for example high-pressure can be conducted. Hence, the amount of foreign material on a surface of the component carrier or the tray is reduced.

According to a further exemplary embodiment, the packing apparatus comprises a flipping arrangement configured for flipping the component carriers after front side cleaning and before back side cleaning, for example by the above described cleaning arrangement. The front side and the back side are opposed surfaces of the component carrier. The front side and the back side form main surfaces of the component carrier providing e.g. functional interfaces or having electronic components and signal traces etc. attached and formed thereon. Hence, the flipping arrangement may be interposed between the gating arrangement and the cleaning arrangement. For example, the gating arrangement measures the gating criterion of one surface of the component carrier. Next, the component carrier may be flipped upside down and the surfaces will be cleaned by the cleaning arrangement before transporting the flipped component carrier back to the gating arrangement for measuring the gating criterion of the other surface of the component carrier.

The flipping unit may comprise for example a flipping table onto which a component carrier can be fixed. The flipping unit may comprise for example clamping elements for clamping the component carrier to the flipping table. Alternatively, the flipping table may comprise vacuum holes for sucking air such that the component carrier structures may be fixed by under pressure. The flipping table may flip about 180° and hence, upon release of the component carrier structure, the component carrier structure is flipped around.

According to a further exemplary embodiment, the tracing arrangement is an optical tracing arrangement configured for optically detecting tracing information of the component carriers. The optical tracing arrangement comprises for example cameras for taking picture of respective geometry of the component carrier and the tray, respectively, or for determining the above described identification marks. Hence, the detection of tracing information of the component carrier provides an improved detection of defect component carriers and therefor lead to a higher quality of the overall process.

According to a further exemplary embodiment, the packing apparatus comprises a stacking arrangement configured for stacking trays each accommodating component carriers. The stacking arrangement comprises for example a supporting table, onto which a first bottom tray comprising a component carrier may be arranged. On top of the respective lower tray, further trays can be placed for forming a bundle of trays. The trays may be handled by a manipulator, for example. A precise traceability leads to an improved process quality, since the location of all component carriers and the trays, respectively, is known and traceable. Individual tray(s) may comprise for example protrusions (at least one, preferably a plurality), protruding from the frontside (top) surface in stack thickness direction. Additionally the trays comprise cavities inverse to the protrusions on the top side on the bottom side, such that the protrusions on the below located tray fits in the above located cavities. This geometric feature may enhance stacking stability of the trays.

According to a further exemplary embodiment the packing apparatus comprises a bundling arrangement configured for bundling stacked trays accommodating component carriers. The bundling arrangement receives a stacked trays from the stacking arrangement. The bundling arrangement is formed for fixing the stacked trays together for forming a transportable bundle of stacked trays. For example, the bundling arrangement may comprise a foil device, which envelopes the stack trays with the foil. Additionally, the bundling device may comprise a strip device for strapping bundling strip around the stack trays.

According to a further exemplary embodiment the bundling arrangement is configured for arranging the stacked trays between a bottom-sided stiffener sheet and a top-sided stiffener sheet. The respective stiffener sheet comprise the stiffness for the stack the trays and the component carriers, respectively. The stiffener sheets protect the stacked trays from loads acting from the top or from the bottom against the respective stack trays. According to a further exemplary embodiment the packing apparatus comprises a bundling arrangement configured for bundling stacked trays accommodating component carriers. The bundling arrangement receives a stacked trays from the stacking arrangement. The bundling arrangement is formed for fixing the stacked trays together for forming a transportable bundle of stacked trays. For example, the bundling arrangement may comprise a foil device, which envelopes the stack trays with the foil. Additionally, the bundling arrangement may comprise a strip device for strapping bundling strip around the stack trays. Alternatively, the bundling arrangement may bundle a plurality of stacked trays adjacent to each other (sharing a common surface together) together.

According to a further exemplary embodiment the packing unit is configured for executing pre-packing followed by vacuum packing. For example, the bundling arrangement pre-packs the stacked trays by enveloping the stack trays with a plastic foil. The plastic foil may form an airtight hull for the bundle of stacked trays. Next, at a vacuum arrangement comprising a vacuum pump, air is sucked out of the hull for providing a vacuum. Hence, space may be saved and interaction of the component carriers with air/gas, which may cause corrosion/oxidation is prevented.

According to a further exemplary embodiment, the packing unit is configured adding a packing identifier structure to the pack of trays of component carriers. The packing identification structure may be a detectable structure, such as a sticker or an RFID tag which comprises respective information about the stacked component carriers, such as product numbers, transportation information or test certificates of the respective component carriers.

According to a further exemplary embodiment, the packing apparatus comprises a loader unit for automatically loading the component carriers into the packing apparatus. For example, a package of component carriers to be packed may be transferred to the packing arrangement. From the stack of component carriers, the loader unit loads a respective component carrier one after another. For example, the loader unit may comprise a respective manipulator which grips the top component carrier of the stack and feeds the component carrier structure to the gating arrangement, for the further processing. The manipulator may mechanically grip the component carrier and/or may carry the component carrier by suction, for example if the manipulator comprises a suction cup for fixing the component carrier structure.

According to a further exemplary embodiment, the packing apparatus comprises an unloader unit for automatically unloading component carrier packs out of the packing apparatus. The unloader unit may be formed similar to the loader unit, wherein the unloader unit may comprise a respective manipulator which grips a component carrier pack that is located in the respective e.g. vacuum packing station. The manipulator transfers the gripped pack to a desired location outside of the packing apparatus for further processing.

According to a further exemplary embodiment, the packing apparatus comprises at least one air filter mechanism for filtering air inside of the packing apparatus for removing foreign particles. The filter mechanism may comprise a blower for blowing air out of the packing arrangement. Hence, a clean environment in the machine is provided and the amount of foreign material in the package is reduced.

According to a further aspect of the present invention, a component carrier pack is presented. The component carrier pack comprises a plurality of component carriers comprising a component carrier identifier structure detectable for retrieving tracing information assigned to the respective component carrier. Furthermore, the component carrier pack comprises a packing structure enclosing the component carriers and comprising a packing identifier structure detectable for retrieving tracing information assigned to the component carrier pack. A packed unit according to the present invention comprises a packaging structure enclosing a component carrier bundle consisting of a plurality of trays each accommodating at least one component carrier. According to a further exemplary embodiment, the component carrier identifier structure comprises a QR code. According to a further exemplary embodiment, the component carrier pack identifier structure comprises a QR. code. Hence, a fast traceability can be provided so that information about the component carriers in the stack can be quickly retrieved.

According to a further exemplary embodiment, the component carrier packs comprise a plurality of trays each accommodating a plurality of the component carriers and each comprising a tray identifier structure, in particular a QR code, detectable for retrieving tracing information assigned to the respective tray.

According to a further exemplary embodiment, the trays are stacked and bundled by the packing structure.

According to a further aspect, a system is presented, comprising a plurality of above described component carrier packs and a database comprising a plurality of data sets each assigned by the respective component carrier identifier structure and/or the packing identifier structure to a respective one of the component carrier packs.

The aspects defined above and further aspects of the invention are apparent from the examples of embodiment to be described hereinafter and are explained with reference to these examples of embodiment.

Brief Description of the Drawing

Fig. 1 shows a schematic view showing a packaging apparatus according to an exemplary embodiment of the present invention.

Fig. 2 shows a schematic view showing a gating arrangement according to an exemplary embodiment of the present invention. Fig. 3 shows a schematic view showing a bundling arrangement according to an exemplary embodiment of the present invention.

Fig. 4 shows a schematic view showing a bundle of trays according to an exemplary embodiment of the present invention.

Fig. 5 shows a schematic view showing a packaging structure enclosing a component carrier pack according to an exemplary embodiment of the present invention.

Fig. 6 shows a schematic view showing a bundle of trays with respective tray identifiers and component carrier identifiers according to an exemplary embodiment of the present invention.

Detailed Description

The illustration in the drawing is schematic. It is noted that in different figures, similar or identical elements or features are provided with the same reference signs or with reference signs, which are different from the corresponding reference signs only within the first digit. In order to avoid unnecessary repetitions elements or features which have already been elucidated with respect to a previously described embodiment are not elucidated again at a later position of the description.

Further, spatially relative terms, such as "front" and "back", "above" and "below", "left" and "right", et cetera are used to describe an element's relationship to another element(s) as illustrated in the figures. Thus, the spatially relative terms may apply to orientations in use which differ from the orientation depicted in the figures. Obviously all such spatially relative terms refer to the orientation shown in the figures only for ease of description and are not necessarily limiting as an apparatus according to an embodiment of the invention can assume orientations different than those illustrated in the figures when in use. Fig. 1 shows a schematic view showing a packaging apparatus 100 for automatically packing component carriers 201 according to an exemplary embodiment of the present invention. The packing apparatus 100 comprises a gating arrangement 110 configured for allowing only component carriers 201 to proceed with packing which meet at least one predefined gating criterion, a tracing arrangement 120 configured for tracing the component carriers 201 during processing by the packing apparatus 100, and a packing unit 130 for packing the traced component carriers 201, which meet the at least one predefined gating criterion, to a component carrier pack 106.

A loader unit 151 is provided for automatically loading the component carriers 201 into the packing apparatus 100. For example, a package of component carriers 201 to be packed may be transferred to the packaging apparatus 100. From the stack of component carriers 201, the loader unit 151 loads a respective component carrier 201 one after another to the packaging arrangement 100. The loader unit 151 comprises a respective manipulator which grips the top component carrier 201 of the stack and feeds the component carrier 201 to the gating arrangement 110 for the further processing. Conveyor lines (belts) may form a first input line 104 and a second input line 105 on which respective component carriers 201 may be transported to the gating arrangement 110.

The gating arrangement 110 comprises for example several sensors, such as an optical sensor, e.g. a camera, which analyzes if the component carriers 201 and/or a respective bundle 102 of component carriers 201 or also respective trays 101 carrying the component carriers 201 comply with certain gating criterions, such as a warpage ofa component carrier 201 or a tray 101 as described below.

If the respective component carrier 201 or the respective tray 101 fulfills the respective gating criterion, the gating arrangement 110 releases the respective component carrier 201 to proceed with packing which meet at least one predefined gating criterion. Along the complete packaging process, between several packaging steps, a gating of the gating arrangement 110 may be located, so that along the complete packaging process quality control and hence the respective gating criterion can be verified.

In order to trace the component carriers 201 during the packaging process, the packing apparatus comprises the tracing arrangement 120 configured for tracing the component carriers 201 during processing by the packing apparatus. Hence, the respective component carrier 201 and/or tray 101 may comprise respective identifiers 401, that can be recorded by the tracing arrangement 120, such that the tracing arrangement 120 can verify the component carrier 201 and/or tray 101. The tracing arrangement 120 comprises a plurality of tracing sensors, such as cameras, that can be arranged at several stations throughout the packaging apparatus, so that along the complete packaging process, the respective component carriers 201 to be packed can be traced.

If the component carrier 201 fulfills the gating criterion, finally a certain stack of component carriers 201 can be packed to a bundle 102 and furthermore, after being fixed together by a packing structure 103, to a carrier pack 106, respectively for transportation.

Automatic manipulator devices, such as robots or conveying belts, transport the component carriers 201 between the stages of the packaging apparatus 100.

The gating arrangement 110 receives the component carrier 201 which is arranged within a carrying tray 101. The gating arrangement 110 is configured for allowing only component carriers 201 to proceed with packing which meet the gating criterion that warpage of a tray 101 accommodating component carriers 201 is below a predefined warpage threshold value.

Usually, the component carriers 201 are arranged for transportation in trays 101 which form a flat stable structure for carrying the carriers. The trays 101 form a carrying frame forming a support surface onto which the component carriers 201 can be attached. For transportation, a plurality of trays 101 each carrying one or a plurality of component carriers 201 may be stacked on top of each other and fixed by a packing structure 103 for forming the carrier pack 106. However, if the trays 101 are deformed and thus comprise a certain warpage, the support surface of the trays 101 and hence also the component carriers 201 arranged onto the support surface are prone to warpage as well.

Hence, if a certain amount of warpage is detected, the trays 101 can be still used for carrying component carriers 201. However, if the warpage of the trays 101 exceed a certain warpage threshold value, the respective trays 101 are taken out of the packing process. The gating apparatus comprises a first warpage detection section, wherein the warpage of each tray 101 is checked before entering the packing process. Additionally, after several stations of the packing process, such as cleaning, flipping and stacking trays 101, a further second warpage detection section is arranged, wherein the second warpage detection section is configured for detecting the warpage of several trays 101 stacked together and which need to be checked. There may be a need therefore, because during the single packaging steps, the trays 101 may deform such that also further warpage detection may be necessary.

The gating criterion regarding warpage may be determined by optical sensors, for example by cameras. For example, the cameras they detect, if corner regions of a respective tray 101 have different heights. If the heights of the corners different to each other, this may be a hint that the tray 101 is deformed. The warpage criterion may define for example a height difference between corner sections of the tray 101. If the difference between the heights of the corners section of the tray 101 exceed a predefined threshold value, the respective tray 101 is taken out of the packing process.

The gating arrangement 110 is configured for allowing only component carriers 201 to proceed with packing which meet the gating criterion that a position of component carriers 201 accommodated in a tray 101 meet a predefined position criterion. The position of the component carrier 201 on the respective tray 101 has to be determined, such that for example after a stacking of the trays 101, misaligned component carriers 201 and the tray 101 will not be damaged. The predefined position criterion may define an allowable offset of the component carrier 201 with respect to an ideal component carrier position in the tray 101. The gating arrangement 110 comprises a camera device to take a picture of the component carriers 201 in the tray 101 for evaluating if the position complies with the predefined position criterion. The gating arrangement 110 determines the position of the corners of the component carrier 201 and/or the edges of the component carrier 201 on the tray 101. Additionally, the tray 101 may comprise identification markers. The gating arrangement 110 may determine the distance between respective edges or corners of the component carrier 201 to the identification markers, such that from the respective pictures the position of the component carrier 201 on the tray 101 is determined. Specifically, the gating arrangement 110 comprises a plurality of camera devices throughout the packing procedure for determining plurality of stations of the packing procedure the position of the component carrier 201 on the tray 101.

The tracing arrangement 120 comprises an identification unit 121, such as an optical tracing arrangement 120 configured for optically detecting tracing information of the component carriers 201. The optical tracing arrangement 120 comprises for example cameras for taking picture of respective geometry of the component carrier 201 and the tray 101, respectively or for determining the above described identification marks. The tracing arrangement 120 is configured for tracing the component carriers 201 by detecting component carrier identifier structures 402 on the component carriers 201 and for storing corresponding component carrier tracing information.

Each component carrier 201 may comprise a specific identifier structure, such as a serial number or a specific laser mark (e.g. an RFID-Tag or 2D. ID (i.e. a QR- Code etc.), so that a unique identification (unique ID) for each component carrier 201 is given and stored in a database. Hence, the tracing arrangement 120 may comprise tracing elements, such as cameras, at several positions in the packing process, so that upon detecting the identifier, it can be verified which component carrier 201 is on which position in the packing process. If a defect of a component carrier 201 is determined, the defect component carrier 201 can be registered in the database storing the unique identification tags for each component carrier. The tracing arrangement 120 provides the location and information of the component carrier 201.

The tracing arrangement 120 is further configured for tracing the component carriers 201 by detecting tray identifier structures 401 on trays 101 accommodating the component carriers 201 and for storing corresponding tray 101 tracing information. Similar to the component carriers 201, each tray 101 may also comprise a specific identifier structure, such as a serial number or a specific laser mark (e.g. an RFID-Tag or 2D. ID (i.e. a QR-Code etc.), so that a unique identification (unique ID) for each tray 101 is given and stored in a database. Hence, the tracing arrangement 120 may comprise tracing elements, such as cameras, at several positions in the packing process, so that upon detecting the identifier of the tray 101, it can be verified which tray 101 is on which position in the packing process. If a defect of a tray 101 is determined, the defect tray 101 can be registered in the database storing the unique identification tags for each tray 101. The tracing arrangement 120 provides the location and information of the component carrier 201.

After the first gating arrangement 110, a cleaning arrangement 140 is provided configured for cleaning the component carriers 201 before packing. The cleaning arrangement 140 comprises for example high-pressure nozzles such that by high-pressure residues or other particles can be blown away from the component carriers 201 for cleaning purposes. Throughout the whole packing process, plurality of cleaning devices, specifically high-pressure cleaning devices, of the cleaning arrangement 140 are provided.

After the first gating arrangement 110, the component carriers 201 and the trays 101 may be flipped in the flipping station 141. It may be necessary to check after the flipping of the tray 101, if the component carrier 201 on the tray 101 still complies with the predefined position criterion. The flipping arrangement 141 is configured for flipping the component carriers 201 after front side cleaning and before back side cleaning, for example by the cleaning arrangement 140. Hence, the flipping arrangement 141 may be interposed between the gating arrangement 110 and the cleaning arrangement 140. For example, the gating arrangement 110 measures the gating criterion of one surface of the component carrier. Next, the component carrier 201 may be flipped upside down and the surfaces will be cleaned by the cleaning arrangement 140 before transporting the flipped component carrier 201 back to the gating arrangement 110 for measuring the gating criterion of the other surface of the component carrier.

Hence, after flipping, the component carrier 201 on the tray 101 is transported back to the gating arrangement 110 for checking the position of the component carrier 201 on the tray 101. Further, e.g. after a further passing of the cleaning arrangement 140, the component carrier 201 on the tray 101 move on to the stacking arrangement 131.

The stacking arrangement 131 is configured for stacking trays 101 each accommodating at least one component carrier 201. The stacking arrangement 131 comprises for example a supporting table, onto which a first bottom tray 101 comprising a component carrier 201 may be arranged. On top of the respective lower tray 101, further trays 101 can be placed for forming a bundle of trays 101. The trays 101 may be handled by a manipulator, for example.

After the trays 101 with the component carriers 201 are stacked, the stacked trays 101 move on to a bundling arrangement 132. There, the stacked trays 101 are arranged between a bottom-sided stiffener sheet 134 and a top-sided stiffener sheet 133. The respective stiffener sheet 133, 134 comprises provides stiffness for the trays 101 and the component carriers 201, respectively. The stiffener sheets 133, 134 protect the stack from loads and/or other damage sources acting from the top or from the bottom against the respective stack trays 101.

The gating arrangement 110 may comprise a bundle gating unit 136 configured for allowing only component carriers 201 to proceed with packing which meet the gating criterion that an overlap of component carriers 201 accommodated in a tray 101 beyond the tray 101 meet a predefined overlap criterion. Hence, after the component carriers 201 and the respective trays 101 are stacked above each other, it has to be confirmed, that no lateral misalignment between the trays 101 of component carriers 201 exists. Hence, the position criterion determines that a threshold value for a respective offset between the trays 101 carrying the component carriers 201 is fulfilled. The gating arrangement 110 comprises a camera device to take a picture of the component carriers 201 in the tray 101 for evaluating if the position complies with the predefined position criterion and to check the amount of component carriers 201 stacked above each other and form a bundle of component carriers 201. The camera device is configured for taking a top picture of the top of the bundle and a bottom picture of the bundle, wherein the gating arrangement 110 is configured for comparing the top picture and the bottom picture for checking the predefined position criterion. For example, the camera device comprises a camera element arranged above the stack of component carriers 201 and the further camera element arranged below the stack of component carriers 201. Hence, respective top and bottom pictures can be taken. Specifically, two steps for checking the overlap criterion may be accomplished. First, at the first station, first station a height of the trays 101 is checked if for example more component carriers 201 are positioned in one carrier of tray 101. Next, the top picture and the bottom picture is compared, and if the picture of top and bottom pictures show the same contours of the tray 101, it means the two trays 101 are stacked with a correct overlap. Furthermore, the gating arrangement 110 may determine, if the trays 101 and the component carriers 201 in the bundle are exposed to stress or load which can damage the respective component carriers 201. The gating arrangement 110 comprises a force sensor which is configured for detecting a force load of the bundle of trays 101, wherein the force load of the bundle of trays 101 is indicative for the quality property of the bundle of trays 101. For example, the force may be the pressure force or the weight force acting between two adjacent stacked trays 101. For example, if too much weight acts on a lowermost tray 101 in the bundle, damage may appear. If a respective weight force exceeds a predefined threshold value, the quality property criterion is not fulfilled and the bundle 102 is not proceeded in the next packing step.

Furthermore, the gating arrangement 120 checks, if a height of a bundle 102 of trays 101 accommodating component carriers 201 meets a predefined height criterion. For example, the height may be measured by a position sensor and a camera, respectively. If the height of a bundle 102 of trays 101 exceeds a predefined height limit is the height criterion, the respective bundle 102 is sorted out and stopped from the further packing procedures. If the bundle 102 of trays

101 is higher than the predefined height limit, this can be a hint for a misalignment or a damage of a respective tray 101. The position sensor checks also, if a misalignment of the side walls of a bundle of the trays 101 meet a predefined position criterion.

In a further packing unit 137, the stacked trays 101 are pre-packed by enveloping the bundle 102 of trays 101 with a plastic foil. The plastic foil may form an airtight hull for the bundle of stacked trays 101. Next, at a vacuum packing station 135 comprising a vacuum pump, air is sucked out of the hull for providing a vacuum for forming the packing structure 103 around the bundle 102. After the packing structure 103 rigidly encloses the bundle 102, the bundle

102 forms the packed unit 106. A packed unit 106 comprises stacked trays 101 hosting at least one component carrier 201 in each tray 101, e.g. a top-sided stiffener sheet 133, e.g. a bottom-sided stiffener sheet 134 and the hull (i.e. the packing structure 103).

Finally, the packing apparatus comprises an unloader unit 152 for automatically unloading the packed unit 106 out of the packing apparatus 100. The unloader unit 152 may be formed similar to the loader unit 151, wherein the unloader unit 152 may comprise a respective manipulator which grips a component carrier pack 106 that is located in the respective e.g. vacuum packing station 135. From the unloader unit 152, the manipulator transfers the gripped packed units 106 to a desired location outside of the packing apparatus 100 for further processing.

The packing apparatus 100 comprises at least one air filter mechanism 150 for filtering air inside of the packing apparatus for removing foreign particles.

Fig. 2 shows a schematic view showing a gating arrangement 110 according to an exemplary embodiment of the present invention. A tray 101 comprises e.g. two component carriers 201. An optical sensor 203 of the gating arrangement 110 checks for example the position of the component carriers 201 in the respective tray 101. The identification arrangement 120 comprises for example a sensor 202, such as an RFID sensor for detecting a tray identifier 401 or a component carrier identification structure 402 in order to identify the component carrier 201 and the tray 101, respectively.

Fig. 3 shows a schematic view showing a bundling arrangement 132 according to an exemplary embodiment of the present invention. The trays 101 are stacked in a component carrier bundle 102 and secured by a bundling strip which is wounded around the bundle 102 in the bundle arrangement 132. At the upper side and at the lower side a respective top-sided stiffener sheet 133 and a bottom-sided stiffener sheet 134 is arranged. A bundle gating unit 136, such as an optical sensor or a load sensor, checks, if a respective gating criterion is met before moving on to the packing unit 137 and the vacuum packing station 135.

Fig. 4 shows a schematic view showing a component carrier bundle 102 according to an exemplary embodiment of the present invention. Each tray 101 comprises at least one component carrier 201 comprising a component carrier identifier structure 402 detectable for retrieving tracing information assigned to the respective component carrier 201. The component carrier identifier structure 402 comprises a QR code. The component carrier bundle 102 consists of a plurality of trays 101 each accommodating at least one component carrier 201 and each comprising a tray identifier structure 401, in particular a QR code, detectable for retrieving tracing information assigned to the respective tray 101.

The tracing arrangement 120 is configured for tracing the component carriers 201 by detecting tray identifier structures 402 on trays 101 accommodating the component carriers 201 and for storing corresponding tray tracing information.

As can be taken from Fig. 4, the trays 101 comprise e.g. accommodation cavities in which the component carrier 201 are accommodated. The top surface of a component carrier 201 may not be in direct contact with the tray 101, such that e.g. the component carrier identifier structure 402 can be detected. Hence, a good protection of the component carrier 201 is ensured. As can be seen in Fig. 4, the surface of the tray 101 may be located higher in stack thickness direction so that the component carrier 201 is not protruding out of the tray 101. Alternatively, the top surface of the component carrier 201 and the tray 101 may be flush.

The trays 101 may further comprise stacking elements 403 that may be formed of protrusions, such as stacking pins, wherein the stacking elements 403 are formed for being engaged in respective recesses of a subsequent tray 101 in the stack of trays 101. The trays 101 may comprise stacking elements 403 protruding from a top surface and a respective recess formed in a respective bottom side. Hence, the stacking elements 403 of a lower tray 101 may be engaged by a respective recess of an upper tray 101.

Fig. 5 shows a schematic view showing a packed unit 106 comprising a packaging structure 103 enclosing a component carrier bundle 102 consisting of a plurality of trays 101 each accommodating at least one component carrier 201 according to an exemplary embodiment of the present invention. According to a further exemplary embodiment, the trays 101 are stacked and enclosed by the packing structure 103. The packing unit 137 is configured adding a packing identifier structure 501 to the packaging structure 103 of the packed unit 106. The packing identifier structure 501 may be a detectable structure, such as a QR code sticker or an RFID tag which comprises respective information about the stacked component carriers 201, such as product numbers, transportation information or test certificates of the respective component carriers 201. The tracing arrangement 120 is configured for tracing the component carriers 201 by detecting packing identifier structures 501 on a packing structure 103 enclosing the component carriers 201 and for storing corresponding packing structure tracing information.

The packing structure 103 may be a carton box or a (plastic) foil enveloping the bundle 102 of trays 101 accommodating the component carriers 201. The packing structure 103 may also be a pallet, onto which the bundle 102 is arranged. Similar to the component carriers 201, each packing structure 103 may also comprise a specific packing identifier structure 501, such as a serial number or a specific laser mark (e.g. an RFID-Tag or 2D. ID (i.e. a QR-Code etc.), so that a unique identification (unique ID) for the packed unit 106 is given and stored in a database.

Fig. 6 shows a schematic view showing a component carrier bundle 102 comprising trays 101 accommodating component carriers 201 with respective tray identifiers 401 and component carrier identifiers 402 according to an exemplary embodiment of the present invention.

A respective system comprises all information of a plurality of above described component carrier bundles 102 and a database comprising a plurality of data sets each assigned by the respective tray identifiers 401, component carrier identifier structures 402 and/or the packing identifier structures 501 to a respective one of the component carrier packs 106.

It should be noted that the term "comprising" does not exclude other elements or steps and the "a" or "an" does not exclude a plurality. Also elements described in association with different embodiments may be combined. It should also be noted that reference signs in the claims shall not be construed as limiting the scope of the claims. Implementation of the invention is not limited to the preferred embodiments shown in the figures and described above. Instead, a multiplicity of variants are possible which use the solutions shown and the principle according to the invention even in the case of fundamentally different embodiments.

Reference Numerals:

100 Packing apparatus

101 tray

102 component carrier bundle

103 packing structure

104 first input line

105 second input line

106 packed unit/ component carrier pack

110 gating arrangement

120 tracing arrangement

121 identification unit

130 packaging unit

131 stacking arrangement

132 bundling arrangement

133 top-sided stiffener sheet

134 bottom-sided stiffener sheet

135 vacuum packing station

136 bundle gating unit

137 packing unit

140 cleaning arrangement

141 flipping arrangement/station

150 filter mechanism

151 loader unit

152 unloader unit

201 component carrier

202 sensor

203 optical sensor

301 bundling strip

401 tray identifier

402 component carrier identifier structure

403 stacking element

501 packing identifier structure