Manufacturing method for electronic or electric products such as flat-panel display devices and band-shaped package therefor

• US 20050241988A1
• Filed: 04/01/2005
• Published: 11/03/2005
• Est. Priority Date: 04/02/2004
• Status: Active Grant

• Current Assignee: Japan Display Central Incorporated (Japan Display Incorporated)
• Original Assignee: Toshiba Matsushita Display Technology (Japan Display Incorporated)
• Inventors: Shimada, Osamu, Iizuka, Takayuki, Hirata, Katsuyasu, Ohashi, Kazuhiro, Shintani, Hiroshi
• Granted Patent: US 7,757,464 B2
• Time in Patent Office: Days
• US Class Current: 206/701
• CPC Class Codes: H05K 13/0084 Containers and magazines for components, e.g. tube-like magazines

Abstract

A method for manufacturing electronic or electric products such as flat-panel display devices, for coping with change or variations of dimensions of the products and for curbing damage or fracture on the products and reducing recovery cost for containers, according to one embodiment, comprising; sequentially placing first flat electronic or electric products as to be sandwiched by a resin-sheet band formed of one or pair of band-shaped flat resin sheet and as to be arrayed in a row; forming joined areas by bonding faces of the resin-sheet band as to form receptacles respectively for the first flat electronic or electric products; thus forming a band-shaped package; and then transporting or storing such array of the first flat electronic or electric products in the band-shaped package as to be used for producing second electronic or electric products.

Claims

1. A method for manufacturing electronic or electric products, comprising:

sequentially placing first flat electronic or electric products as to be sandwiched by a resin-sheet band formed of one or pair of band-shaped flat resin sheet and as to be arrayed in a longitudinal direction of the resin-sheet band;

forming joined areas by bonding or fusing faces of the resin-sheet band as to form receptacles respectively for the first flat electronic or electric products;

thus forming a band-shaped package in which the first flat electronic or electric products are arrayed in a row in a longitudinal direction; and

then transporting or storing such array of the first flat electronic or electric products in the band-shaped package as to be used for producing second electronic or electric products.

2. A method for manufacturing electronic or electric products, according to claim 1, transparent at least either for obverse and reverse faces of the band-shaped package.

3. A method for manufacturing electronic or electric products, according to claim 1, said first flat electronic or electric products being display panels before or after attaching connector boards;

and the display panel having a diagonal dimension of viewing angle no more than 10 inch.

4. A method for manufacturing electronic or electric products, according to claim 1, positioning of said first flat electronic or electric products being made when forming the joined areas.

5. A method for manufacturing electronic or electric products, according to claim 1, the band-shaped package having fringe extension areas extended from the resin-sheet band on both sides on a row of the receptacles.

6. A method for manufacturing electronic or electric products, according to claim 1, the joined areas being peel-wise separatable;

and the receptacles being sequentially opened up by sequential pulling apart of the obverse and reverse sheet parts, thereby the first electronic or electric parts sequentially becoming retrievable.

7. A method for manufacturing electronic or electric products, according to claim 1, the resin-sheet band being provided with to-be-broken portions on at least one of the obverse and reverse sheet parts;

and the receptacles being sequentially opened up by sequential tearing apart along the to-be-broken portions, thereby the first electronic or electric parts sequentially becoming retrievable.

8. A method for manufacturing electronic or electric products, according to claim 7, the to-be-broken portions being comprised of ones extending along longitudinal direction of the band-shaped package and/or ones extending along outlines of the each electronic and electric products.

9. A method for manufacturing electronic or electric products, according to claim 6 or 8, the band-shaped package comprising a double-margin fringe extension areas at which obverse and reverese sheet parts are overlapped without being joined and one of the sheet parts protrude outward from the other one of the sheet parts;

and said peel-wise separating or said tearing apart being made by pulling apart fringe portions of the sheet parts at the dougle-margin fringe extension areas.

10. A method for manufacturing electronic or electric products, according to claim 5, the band-shaped package being wound in a convolution during said transporting or storing.

11. A method for manufacturing electronic or electric products, according to claim 5, the band-shaped package being folded in a waveform or in a zigzag seen from its width direction, during said transporting or storing.

12. A method for manufacturing electronic or electric products, according to claim 10 or 11, the obverse and reverse sheet parts being arranged substantially vertical during said transporting or storing.

13. A method for manufacturing electronic or electric products, according to claim 11, the obverse and reverse sheet parts being arranged substantially horizontal during said transporting or storing.

14. A method for manufacturing electronic or electric products, according to claim 10 or 11, air or other gas is held in each of the receptacles as a shock absorber.

29. A method for manufacturing electronic or electric products, according to claim 1, further comprising:

pulling out first band part from the resin-sheet band and wind around the first driving roller and pulling out second band part from the resin-sheet band and wind around the second driving roller; and

then,

driving the first and second driving roller as to be synchronized with each other as to pull the first and second band parts in opposite direction;

thereby sequentially pulling out and separating the first and second band parts from the resin-sheet band by tearing apart of the resin sheet or by peel-wise separating of the sheet parts, and in same time, introducing the band-shaped package into a place of the separating.

30. A method for manufacturing electronic or electric products, according to claim 29, further comprising:

winding the first and second band part around a centrally bulging roller, diameter of which is smoothly increased as come closer to central portion as leaving from end portions, at before feeding to the first and second driving rollers; and

the first and second band part being dischareged after passing the first and second driving rollers respecetively.

31. A method for manufacturing electronic or electric products, according to claim 29, further comprising:

detecting a state where the first electronic or electric products are placed on the first band part as being retrievalble and sent out to a predetermined retrieval position, and then stopping the driving of the first and second driving rollers; and

picking up the first electronic or electric products and feeding them to process of assembling the second electronic or electric products.

15. A band-shaped package for electronic or electric products, comprising:

a resin-sheet band formed of one or pair of band-shaped flat resin sheet;

joined areas joining faces of the resin-sheet band by adhesion or fusion;

receptacles formed by the joined areas;

flat electronic or electric products arrayed in a row or rows, each of said flat electronic or electric products being received in one of the receptacles and as being held in a predetermined position on the resin-sheet band by the joined areas;

and fringe extension areas extended from the resin-sheet band on opposite sides sandwiching the row or rows of the receptacles.

16. A band-shaped package for electronic or electric products according to claim 15, the resin-sheet band being transparent at least either for obverse and reverse faces of the band-shaped package.

17. A band-shaped package for electronic or electric products according to claim 15, the resin-sheet band having antistatic property on at least either of the obverse and reverse sheet parts of the band-shaped package.

18. A band-shaped package for electronic or electric products according to claim 15, wherein the joined areas being peel-wise separatable and/or to-be-broken portions are formed at least one of the obverse and reverse sheet parts;

and the receptacles being able to be sequentially opened up by sequential pulling apart of the obverse and reverse sheet parts so as to make the first electronic or electric parts retrievable.

19. A band-shaped package for electronic or electric products according to claim 18, the to-be-broken portions being comprised of ones extending along longitudinal direction of the band-shaped package and/or ones extending along outlines of the each electronic and electric products.

20. A band-shaped package for electronic or electric products according to 15, at least one the fringe extension areas being a part where obverse and reverese sheet parts are overlapped without being joined and one of the sheet parts protrude outward from the other one of the sheet parts by 10 mm or more.

21. A band-shaped package for electronic or electric products, according to anyone of claims 18-20, the peel-wise separating or tearing apart of the resin sheet along the to-be-broken portions being able to be made in respect of any one of the receptacles independently from other ones of the receptacles.

22. A band-shaped package for electronic or electric products, according to claim 15, the resin-sheet band being printed with alphabetical or other letters, and/or with bar code, or other marks or symbols for indicating information on device types, device variations, production lots, production dates, destination sites, destination devices or alarms on handling.

23. A band-shaped package for electronic or electric products, according to claim 15, whole or part of the resin-sheet band being colored in a manner inside of the resin-sheet band is visible and color-coding is made for indicating information on device types, device variations, production lots, production dates, destination sites, destination devices or alarms on handling.

24. A band-shaped package for electronic or electric products, according to claim 18, the to-be-broken portions being formd of incisions that are throughholes or recesses;

and the incisions being rectacgular that are long in a direction along or perpendicular to arranging direction of the to-be-broken portions, or square, dogleg or V-shape, or trapezoidal.

25. A band-shaped package for electronic or electric products, according to claim 15,

inside dimension of the receptacles along a longitudinal direction of the band-shaped package being larger than that diameter of the electronic or electric parts in the longitudinal direction by no less than 5 mm and smaller than inside dimension of the electronic or electric parts in width direction of the band-shaped package;

and

inside dimension of the receptacles along the width direction being larger than diameter of the electronic or electric parts in the width direction by no less than 5 mm and smaller than two time of said diameter in the width direction.

26. A band-shaped package for electronic or electric products, according to claim 15, having vacated ones of the receptacles at interval of predetermined number of the receptacles.

27. A band-shaped package for electronic or electric products, according to claim 15, having a lead portion omitted with the receptacles or formed of vacated ones of the receptacles, at one end in longitudinal direction.

28. A band-shaped package for electronic or electric products, according to claim 15, the receptacles being communicated with or not communicated with each other and being closed as to be substantially sealed off from the air;

and inside of the receptacles being filled with inert gas or vacuumed when being sealed, or provided with moisture absorbent or deoxidizer.

32. An unpacking device, for sequentially taking out flat electronic or electric products from a band-shaped package comprised of;

a resin-sheet band formed of one or pair of band-shaped flat resin sheet;

joined areas joining faces of the resin-sheet band by adhesion or fusion;

receptacles formed by the joined areas;

the flat electronic or electric products arrayed in a row or rows, each of said flat electronic or electric products being received in one of the receptacles and as being held in a predetermined position on the resin-sheet band by the joined areas, comprising;

a first driving roller for pulling first band part from the resin-sheet band as being wound around the first driving roller as taken from the resin-sheet band;

a second driving roller for pulling second band part of the resin-sheet band as being wound around the second driving roller as also taken from the resin-sheet band;

a sheet band separating area into which the band-shaped package is sequentially fed in, and in which said first and second band parts are separated from the band-shaped package as being pulled in opposite directions, such sequntial feeding and tract-wise separating being driven solely by the first and second drive rollers; and

a retrieve area which is located between the sheet band separating area and the first driving roller and at which the electronic or electric products are laid on said first part of the resin-sheet band as to be readily taken away.

33. An unpacking device according to claim 32, further comprising:

a first driven roller around which the first band part are wound after coming from the sheet band separating area before winding around the first driving roller;

a second driven roller around which the second band part are wound after coming from the sheet band separating area before winding around the second driving roller; and

discharging areas to which the first and second part are discharged after respectively passing the first and second driving rollers; and

diameter of roller faces of the first and second driven rollers being smoothly increased as come closer to a center as leaving from ends of the rollers.

34. An unpacking device according to claim 33, further comprising:

an optical sensor for capturing the electronic or electric products;

an auto-stopping mechanism for stopping rotational driving of the first and second driving rollers based on detection by the optical sensor; and

a counting and outputting mechanism for obtaining and outputting accumulated number of already unpacked ones of the electronic or electric products.

35. An unpacking device according to claim 33, further comprising a first auxiliary roller coupled to the first driving roller and a second auxiliary roller coupled to the second driving roller;

and

the second driving and driven rollers being arranged at positions higher than the sheet separating area; and

a shaft of the second driving roller being placed at a position lower than that of the second auxiliary roller;

thereby the second band part passed through the second driving and auxiliary rollers being sent upward and then collapsing across the second driving roller when being discharged.

36. An unpacking device according to claim 32, further comprising a timing belt;

and the first and second driving rollers are synchronized by the timing belt and are driven by a motor.

37. An unpacking device according to claim 32, further comprising in the retrieve area;

an underlying support for supporting the electronic or electric products; and

a cutout in the underlying support for facilitating picking up of the electronic or electric products;

the underlying support and the cutout being elongated in dierction of feeding of the first band part.

38. An unpacking device according to claim 32, further comprising;

a blade-shaped fixture being parallel with axis of and close to roller face of the first or second driving roller in a manner to curb twining of the first or second band part around said first or second driving roller;

a tongue-shaped protrusion extended from central portion of the blade-shaped fixture; and

a smaller-diameter portion formed on central portion of said first or second driving roller as to receive the tongue-shaped protrusion.

39. A method of producing a band-shaped package for electronic or electric products, comprising:

arraying flat electronic or electric products between obverse and reverse sheet parts of a resin-sheet band formed of one or pair of band-shaped flat resin sheet, in a row; and

forming joined areas by bonding or fusing the sheet parts as to form receptacles respectively holding the flat electronic or electric products in predetermined positions.

40. A method of producing a band-shaped package for electronic or electric products, according to claim 39, further comprising:

providing the resin-sheet band in which the obverse and reverse sheet parts are continuous each other at a folding portion of the resin sheet, and/or providing a first joined areas along one of fringes of the resin-sheet band, as to form receiving space for the electronic or electric products;

then,

feeding the resin-sheet band while keeping the resin-sheet band as tilted as said one fringe to come to lower position; and

inserting the electronic or electric products from said another fringe, during said feeding.

41. A method of producing a band-shaped package for electronic or electric products, according to claim 40, further comprising:

continuously widening gaps or distance between said obverse and reverse sheet parts at along another fringe opposite to said one fringe, during said feeding of the resin-sheet band, when to make said inserting.

42. A method of producing a band-shaped package for electronic or electric products, according to claim 39, further comprising:

forming vacant ones of the receptacles with interval of predetermined number of the receptacles.

43. A method of producing a band-shaped package for electronic or electric products, according to claim 40, further comprising:

blowing compressed air or compressed gas between the obverse and reverse sheet parts, when to make said inserting.

44. A method of producing a band-shaped package for electronic or electric products, according to claim 40, further comprising:

further feeding the resin-sheet band sliding along a curved face and then vertically downward; and

forming second joined areas during such vertically downward feeding as to complete the receptacles that hold the electronic or electric products as not positionally shiftable.

45. A method of producing a band-shaped package for electronic or electric products, according to claim 44, the curved face having a couout.

46. A packing device comprising:

a horizontally feeding area for feeding a resin-sheet band formed of one or pair of band-shaped flat resin sheet, in a substantially horizontal direction while keeping the resin-sheet band as tilted as one of its fringe to come to lower position; and

a guide for widening gap or distance between obverse and reverse sheet parts of the resin-sheet band as to form an insert area for inserting flat electronic or electric products.

47. A packing device according to claim 46, further comprising:

a nozzle for blowing air or gas into a space between the obverse and reverse sheet parts.

48. A packing device according to claim 46, further comprising:

a vertically feeding area for feeding substantially in vertically downward direction; and

a curved face for feeding thre resin-sheet band as to slide therealong from the horizontally feeding area to the vertically feeding area.

49. A packing device according to claim 48, further comprising:

a sealer or equipment for bonding the sheet parts in the vertically feeding area.

50. A packing device according to claim 48, further comprising:

a cutout in the curved face.

51. A packing device according to claim 48, further comprising:

a pair of rollers for sending out the resin-sheet band from the horizontally feeding area onto the curved face, diameters of said rollers differing from each other.

52. A method for manufacturing electronic or electric products, comprising:

forming joined areas between faces of a resin-sheet band formed of one or pair of band-shaped flat resin sheet, thereby forming receptacles in a row for respectively receiving flat electronic or electric products or parts;

then

placing such products or parts in the receptacles of the resin-sheet band as to form a band-shaped package; and

subsequently taking out such products or parts from the band-shaped package.

53. A method for manufacturing electronic or electric products, according to claim 52, each opening of the respective receptacles being kept as opened so as to allow taking out and re-insertion of the electronic or electric products;

and, in such a state, transporting or storing of the electronic or electric products being made.

54. A method for manufacturing electronic or electric products, according to claim 52, each opening of the respective receptacles being kept as opened so as to allow taking out and re-insertion of the electronic or electric products;

and, in such a state, processing of the electronic or electric products being made.

55. A method for manufacturing electronic or electric products, according to claim 54, said processing being vacuuming, pressurization, heating, cooling, pressing, warm air blowing, gas substitution, aging, or cleaning and being made after charging the band-shaped package into an autoclave, a reactor vessel or a processing chamber.

56. A band-shaped package for electronic or electric products, comprising:

a resin-sheet band formed of one or pair of band-shaped flat resin sheet;

joined areas joining faces of the resin-sheet band by adhesion or fusion;

receptacles formed by the joined areas;

flat electronic or electric products arrayed in a row in one or more predetermined interval, each of said flat electronic or electric products being received in one of the receptacles and as being held in a predetermined position on the resin-sheet band by the joined areas;

and an opening for each one of the receptacles that is kept as opened such that the electronic or electric products are readily taken out and re-inserted.