Manufacturing method for packaging electronic products in a band-shaped package

• US 7,757,464 B2
• Filed: 04/01/2005
• Issued: 07/20/2010
• Est. Priority Date: 04/02/2004
• Status: Expired due to Fees

• Current Assignee: Japan Display Central Incorporated (Japan Display Incorporated)
• Original Assignee: Toshiba Matsushita Display Technology Co Ltd (Japan Display Incorporated)
• Inventors: Shimada, Osamu, Iizuka, Takayuki, Hirata, Katsuyasu, Ohashi, Kazuhiro, Shintani, Hiroshi
• Primary Examiner(s): DESAI, HEMANT
• Application Number:
  US11/096,091
• Publication Number:
  US 20050241988A1
• Time in Patent Office: 1,936 Days
• Field of Search: 534/50, 534/52, 534/55, 534/59, 534/66, 531/76, 535/58, 535/59, 535/62, 535/50, 534/44, 534/56, 531/58
• US Class Current: 53/452
• 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, further 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 anal 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;

further comprising;

pulling out first band part from the resin-sheet band of the band-shaped package to be wound around a first driving roller and pulling out second band part from the resin-sheet band of the band-shaped package to be wound around a 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.

2. A method for manufacturing electronic or electric products, according to claim 1, 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 discharged after passing the first and second driving rollers respectively.

3. A method for manufacturing electronic or electric products, according to claim 2, further comprising:

introducing the band-shaped package onto a platform, on which said separating of the first and second band parts is to be made and the electronic or electric products are to be retrieved, through an introducing or upstream portion of the platform part;

winding the first and second band parts respectively around first and second centrally-bulging bracing rollers, each having a diameter which is smoothly increased as come closer to central portion as leaving from end portions and at between which the first and second band parts are pulled apart to upstream and downstream within a plane along a face of the platform, at before feeding to the first and second driving rollers, said pulling being made between the first and second centrally bulging rollers; and

the first and second band part being discharged after passing the first and second driving rollers respectively;

the second driving roller being disposed to be upwardly distanced from the second bracing roller, which is disposed in vicinity of the introducing portion, so that traverse-wise position of the band-shaped package on the introducing portion is adjusted to come to center of the introducing position by way of that the second band part is pulled upward across a distance between the second bracing roller and the second driving roller.

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

detecting a state where the first electronic or electric products are placed on the first band part as being retrievable 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.

5. A method for manufacturing electronic or electric products, according to claim 4, further comprising:

introducing the band-shaped package onto a platform that has on its top face a cutout window for facilitating the picking up of the first electronic or electric products;

said detecting and said picking up being made at a state a plurality of the first electronic or electric products are arrayed on the top face of the platform.

6. A method for manufacturing electronic or electric products, according to claim 1, wherein by said driving, the first and second band parts are pulled apart to upstream and downstream along a plane of the resin-sheet band.

7. 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;

further comprising;

providing the resin-sheet band in which the obverse and reverse sheet parts are continuous with 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;

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

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

further feeding the resin-sheet band sliding along a smoothly curved face and then vertically downward, the curved face being configured to absorb difference in drop between the right and left sides and to thereby make constant path length along the curved face.

8. A method of producing a band-shaped package for electronic or electric products, according to claim 7, the curved face having a cutout.

9. A method for manufacturing electronic or electric products, according to claim 8, wherein the cutout is positioned at a center between right and left fringe of the curved face and extends in a right-left-wise range corresponding to a space and distance between a roller on right-hand side and a roller on left-hand side, which are for sending out the resin-sheet band from horizontally feeding area onto the curved face.

10. A method for manufacturing electronic or electric products, according to claim 7, further comprising:

adjusting of balance in feeding of the resin sheet band onto the curved face by way of 0.03-0.2 mm difference in diameters between a roller on right-hand side and a roller on left-hand side, which are for sending out the resin-sheet band from horizontally feeding area onto the curved face.

11. A method for manufacturing electronic or electric products, according to claim 7, further comprising:

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.

12. 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 and forming fringe extension areas on both sides on a row of the receptacles in a manner that obverse and reverse sheet parts are overlapped without being joined in the fringe extension areas;

then

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

winding the band-shaped package around a shock-absorbent core to form a packing unit;

placing the band-shaped package in a cage or box, in a convoluted state or in a zigzaggedly folded state or in a state wound around a shock-absorbent core; and

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

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;

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

reverse sheet parts being arranged substantially vertical during said transporting or storing.

13. 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 and forming fringe extension areas on both sides on a row of the receptacles in a manner that obverse and reverse sheet parts are overlapped without being joined in the fringe extension areas;

then

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

placing the band-shaped package in a cage or box, in a convoluted state or in a zigzaggedly folded state or in a state wound around a shock-absorbent core; and

subsequently taking out the band-shaped package from the cage or box and then taking out such products or parts from the band-shaped package;

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;

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

reverse sheet parts being arranged substantially vertical during said placing in the cage or box and during said processing.

14. A method for manufacturing electronic or electric products, according to claim 13, 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.

15. 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 of 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;

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;

feeding the flat resin sheet in a folded state forming a V-shaped section opened upward; and

feeding the first flat electronic or electric products as to be dropped into or slid down into such opening of the V-shaped section so that dropping or sliding down of the first flat electronic or electric products is stopped at a position distanced from bottom end of the V-shaped section by a certain distance as to dispose the first flat electronic or electric products at a certain position in respect of width direction of the resin-sheet band; and

said forming of joined areas being made at a state the first flat electronic or electric products are disposed in said certain position, in a manner that the joined areas are formed along a folded fringe and along an opening of the V-shaped section as well as at each interspace between the first flat electronic or electric products so as to form the receptacles and fringe extension areas on both sides on a row of the receptacles.

16. A method for manufacturing electronic or electric products, according to claim 15, wherein ridges of the first flat electronic or electric products are pressed with a tensional stress of the flat resin sheet when the joined areas are formed so that the first flat electronic or electric products are positioned further and retained in such position.

17. A method for manufacturing electronic or electric products, according to claim 15, wherein obverse and reverse sheet parts are overlapped without being joined in the fringe extension areas.

18. 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 of 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;

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

feeding the flat resin sheet in a folded state forming a V-shaped section opened upward so as to be continuously forwarded by sliding along inner face of a guide having the V-shaped section; and

feeding the first flat electronic or electric products so as to slide down along the reverse sheet of the flat resin sheet that is sliding along a tilted inner face of a guide having a V-shaped section and having a readjusted opening angle of the V-shaped section so that a ridge of each of the first flat electronic or electric products abuts or rests on another inner face of the guide before reaching bottom end of the V-shaped section so as to dispose the first flat electronic or electric products at a certain position in respect of width direction of the resin-sheet band; and

said forming of joined areas being made at a state the first flat electronic or electric products are disposed in said certain position, in a manner that the joined areas are formed along a folded fringe and along an opening of the V-shaped section as well as at each interspace between the first flat electronic or electric products so as to form the receptacles and fringe extension areas on both sides on a row of the receptacles.

19. A method for manufacturing electronic or electric products, according to claim 18, wherein an inner face of the guide is tilted from vertical line by 10 to 25 degrees.