Method and apparatus for flattening cover tape

Abstract

A method and apparatus for flattening cover tape prior to the cover tape being sealed to a carrier tape. The apparatus includes a cover tape flattener with a leading edge angled in the direction of the moving carrier tape and cover tape. The method and apparatus provide for smoothing the cover tape and sealing the cover tape to the carrier tape.

What is claimed is:  
     
         1 . A part packaging apparatus for packaging parts in a carrier tape having serially spaced-apart compartments and at least one flange extending alongside the compartments, and for applying a cover tape over the carrier tape, the carrier tape and cover tape traveling in a downstream direction, the apparatus comprising: 
 a part placement head adapted to position parts in the carrier tape compartments;    a cover tape applicator for laying the cover tape over the carrier tape;    a flattening apparatus having a leading edge that contacts the cover tape to smooth the cover tape; and    a sealing apparatus downstream of the flattening apparatus to seal the cover tape to the carrier tape.    
     
     
         2 . The apparatus of  claim 1 , wherein the flattening apparatus includes a tube roller that defines the leading edge and rolls across the cover tape to smooth the cover tape.  
     
     
         3 . The apparatus of  claim 1 , wherein the flattening apparatus includes at least two tube rollers that each define a leading edge and that together define a peak that points in an upstream direction.  
     
     
         4 . The apparatus of  claim 3 , wherein the leading edges are swept back from the peak in the downstream direction such that wrinkles in the cover tape are smoothed to the sides as the cover tape moves downstream.  
     
     
         5 . The apparatus of  claim 3 , wherein the peak is centered with respect to the side edges of the cover tape.  
     
     
         6 . The apparatus of  claim 3 , wherein the flattening apparatus includes a wire that extends longitudinally through the two tube rollers to define an axis of rotation for the rollers, and wherein the flattening apparatus further includes two mounting clamps securing the ends of the wire to the packaging apparatus, wherein the wire biases the roller tubes into contact with the cover tape.  
     
     
         7 . The apparatus of  claim 1 , wherein the leading edge extends to the outer edges of the carrier tape.  
     
     
         8 . The apparatus of  claim 1 , wherein the flattening apparatus includes a plate that defines the leading edge and that glides across the cover tape to smooth the cover tape.  
     
     
         9 . The apparatus of  claim 8 , wherein the plate includes two edges swept back from the peak in the downstream direction and extending to the outer edges of the carrier tape.  
     
     
         10 . The apparatus of  claim 9 , wherein a wire extends through the plate such that the plate pivots about the wire and wherein the flattening apparatus further includes two mounting clamps securing the ends of the wire to the packaging apparatus, wherein the wire biases the plate into contact with the cover tape.  
     
     
         11 . The apparatus of  claim 8 , wherein the plate includes a cavity on the bottom of the plate to reduce the surface area of the plate that is in contact with the cover tape.  
     
     
         12 . The apparatus of  claim 1 , wherein the cover tape is transparent, and the apparatus further comprising an inspection module to inspect the part in the compartment through the cover tape.  
     
     
         13 . A method of smoothing cover tape and sealing parts in a carrier tape having serially spaced-apart compartments and at least one flange extending alongside the compartments, the method comprising: 
 positioning parts in the carrier tape compartments;    applying the cover tape over the carrier tape;    applying pressure on the cover tape with a flattening apparatus having a leading edge as the cover tape travels in a downstream direction;    smoothing the cover tape as it travels under the leading edge of the flattening apparatus; and    sealing the cover tape to the carrier tape.    
     
     
         14 . The method of  claim 13 , wherein sealing the cover tape to the carrier tape includes applying heat to the carrier tape to activate adhesive on the cover tape.  
     
     
         15 . The method of  claim 13 , wherein sealing the cover tape to the carrier tape includes sealing the cover tape to the carrier tape flange.  
     
     
         16 . The method of  claim 13 , wherein smoothing the cover tape includes removing wrinkles from the cover tape.  
     
     
         17 . The method of  claim 13 , wherein smoothing the cover tape includes removing wrinkles from the middle of the cover tape to the outer edges of the cover tape.  
     
     
         18 . The method of  claim 13 , wherein the flattening apparatus includes a tube roller, and wherein smoothing the cover tape includes rolling the tube roller across the cover tape to smooth the cover tape.  
     
     
         19 . The method of  claim 13 , wherein the flattening apparatus includes a plate, and wherein smoothing the cover tape includes gliding the plate across the cover tape to smooth the cover tape.  
     
     
         20 . The method of  claim 13 , wherein the cover tape is transparent, and further comprising inspecting the part in its compartment through the cover tape with an inspection module after the cover tape is sealed to the carrier tape.  
     
     
         21 . A part packaging apparatus for packaging parts in a carrier tape having serially spaced-apart compartments and at least one flange extending alongside the compartments, and for applying a cover tape over the carrier tape, the carrier tape and cover tape traveling in a downstream direction, the apparatus comprising: 
 a part placement head to position parts in the compartments;    an inspection module to inspect the part in the carrier tape compartment;    a flattening apparatus including 
 a plate that glides across the cover tape, the plate having a leading edge that contacts the cover tape to smooth the cover tape, the leading edge angled in the downstream direction and extending to the outer edges of the carrier tape,  
 a wire that extends through the plate such that the plate pivots about the wire, and  
 at least one mounting clamp securing the end of the wire to the packaging apparatus, wherein the wire biases the plate into contact with the cover tape;  
   a sealing apparatus to seal the cover tape to the carrier tape; and    a seal inspection module to inspect the part in the compartment through the cover tape.    
     
     
         22 . The apparatus of  claim 21 , wherein the plate includes two leading edges that define a peak that points in an upstream direction.  
     
     
         23 . The apparatus of  claim 22 , wherein the leading edges are swept back from the peak in the downstream direction such that wrinkles in the cover tape are smoothed to the sides as the cover tape moves downstream.  
     
     
         24 . The apparatus of  claim 22 , wherein the peak is centered with respect to the side edges of the cover tape.  
     
     
         25 . The apparatus of  claim 21 , wherein the plate includes a cavity on the bottom of the plate to reduce the surface area of the plate that is in contact with the cover tape.  
     
     
         26 . A part packaging apparatus for packaging parts in a carrier tape having serially spaced-apart compartments and at least one flange extending alongside the compartments, and for applying a cover tape over the carrier tape, the carrier tape and cover tape traveling in a downstream direction, the apparatus comprising: 
 a part placement head to position parts in the compartments;    an inspection module to inspect the part in the carrier tape compartment;    a flattening apparatus including 
 a tube roller that rolls across the cover tape to smooth the cover tape, the tube roller having a leading edge that contacts the cover tape to smooth the cover tape, the leading edge angled in the downstream direction and extending to the outer edges of the carrier tape,  
 a wire that extends longitudinally through the tube roller to define an axis of rotation for the roller, and  
 at least one mounting clamp securing the end of the wire to the packaging apparatus, wherein the wire biases the tube roller into contact with the cover tape;  
   a sealing apparatus to seal the cover tape to the carrier tape; and    a seal inspection module to inspect the part in the compartment through the cover tape.    
     
     
         27 . The apparatus of  claim 26 , wherein the flattening apparatus includes at least two tube rollers that each define a leading edge and that together define a peak that points in an upstream direction.  
     
     
         28 . The apparatus of  claim 26 , wherein the leading edges are swept back from the peak in the downstream direction such that wrinkles in the cover tape are smoothed to the sides as the cover tape moves downstream.  
     
     
         29 . The apparatus of  claim 26 , wherein the peak is centered with respect to the side edges of the cover tape.