TAPE FEEDER AND CARRIER TAPE FEEDING METHOD USING SAME

To provide a tape feeder capable of reducing absorption dislocation, a tape feeder according to the present invention is a feeder feeding a carrier tape including a plurality of component storage units of a rectangular shape provided at predetermined intervals in a feed direction. The tape feeder includes a first magnet which is provided below a bottom surface of the component storage unit fed to a feed region so as to extend in the feed direction below one side of the bottom surface of the component storage unit in a width direction, and which attracts a component of the component storage unit fed to the feed region to one side of the bottom surface of the component storage unit in the width direction.

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Description
CROSS REFERENCE TO RELATED APPLICATION

This is a continuation application of PCT application No. PCT/JP2011/000253 filed on Jan. 19, 2011, designating the United States of America.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to a tape feeder.

(2) Description of the Related Art

A component mounting machine is conventionally provided as a machine that mounts an electronic component (hereinafter simply referred to as “component”) onto a substrate. In the component mounting machine, a mounting head takes out a component from a tape feeder by an absorbing nozzle and transfers and mounts it onto the substrate. The tape feeder feeds a carrier tape having a plurality of rectangular component storage units (cavities) which store components and which are provided at predetermined intervals in a feed direction, and conveys the component to a component take-out region where component take-out is performed. Provided as technologies related to the tape feeder are, for example, those described in Japanese Unexamined Patent Application Publication No. 2000-228600 (hereinafter referred to as Patent Reference 1) and Japanese Unexamined Patent Application Publication No. 2009-212194 (hereinafter referred to as Patent Reference 2).

In tape feeders of Patent References 1 and 2, a magnet is provided below an entire bottom surface of a component storage unit fed to a component take-out region. This suppresses, for example, standing of the component at the component storage unit.

SUMMARY OF THE INVENTION

However, a component storage position differs among the component storage units even in the same tape carrier. Therefore, in the component take-out by the mounting head, positional dislocation (absorption dislocation) from a predetermined component absorption position occurs, which consequently deteriorates positional accuracy of the component mounting. For example, carrier tapes of different vendors have different gap sizes at the component storage unit (a sum of gaps in the same direction on a plane between a side surface of the component storage unit and the component in a predetermined direction), but as shown in FIG. 19, with an increase in the gap size at the component storage unit, an amount of positional dislocation increases, so that an absorption error is likely to occur. On the contrary, if the gap size at the component storage unit has become too small, with a decrease in the gap size, the amount of positional dislocation increases, so that the absorption dislocation is likely to occur. That is, in a case where the gap size at the component storage unit is not within a predetermined range (range shown by an arrow in FIG. 19), the absorption dislocation is likely to occur. Therefore, in component mounting by use of carrier tapes of different vendors, it is difficult to control the gap at the component storage unit in a stable manner, so that an absorption error, upright absorption, etc. are likely to occur.

A small-sized component inevitably has a large gap size at the component storage unit. Moreover, upon take-out of the small-sized component, the absorption dislocation has a great influence, resulting in failure to take out the component even if the absorption dislocation is small, so that the absorption error is likely to occur. Therefore, for the mounting of the small-sized component, it is strongly desired in particular to reduce the absorption dislocation.

In view of such a problem, it is an object of the invention to provide a tape feeder capable of reducing absorption dislocation and a carrier tape feeding method using the tape feeder.

To achieve the object described above, a tape feeder according to one aspect of the invention feeds a carrier tape including a plurality of component storage units of a rectangular shape provided at predetermined intervals in a feed direction, and includes a first magnetic force region which is provided below a bottom surface of the component storage unit fed to a feed region so as to extend in the feed direction below one side of the bottom surface in a width direction and which attracts a component of the component storage unit fed to the feed region to one side in the width direction.

Consequently, the component of the component storage unit in the feed region is attracted by the first magnetic force region to one side end of the component storage unit. As a result, all the components of the component storage units are attracted to one side ends of the component storage units for alignment in the feed region, which therefore reduce absorption dislocation.

Here, the tape feeder may include a second magnetic force region which is provided at back in the feed direction with respect to the first magnetic force region below the bottom surface of the component storage unit fed to the feed region and which attracts the component of the component storage unit fed to the feed region towards the back in the feed direction. Further, the first magnetic force region may be formed of a first magnet, the second magnetic force region may be formed of a second magnet, and the first magnet and the second magnet may be integrated together to form an L-shaped magnet.

Consequently, the component of the component storage unit moving in the feed direction in the feed region is attracted by the second magnetic force region to a rear end of the component storage unit in the feed direction by use of a force of feeding a tape. As a result, all the components of the component storage units are attracted to corners of the component storage units for alignment in the feed region, which can therefore further reduce the absorption dislocation.

Moreover, the first magnet may be provided below half of the bottom surface.

This consequently can suppress component standing and failure to perform component absorption by an absorbing nozzle due to a too strong force of attracting the component of the component storage unit by the first magnet.

Moreover, the first magnet may be formed of an elastic body.

This consequently permits a force received by the component and the carrier tape from the absorbing nozzle upon component take-out to be absorbed even when there is a change in a thickness of the carrier tape.

Moreover, the tape feeder may further include an elastic member of a plate-like shape supporting the bottom surface of the component storage unit fed to the feed region, wherein the first magnet may be attached to a surface of the elastic member opposite to a side on which the bottom surface is placed.

This consequently permits easy fitting of the first magnet and reduction of the absorption dislocation with simple configuration. Moreover, a magnetic force is inversely proportional to a square of a distance, but a distance between the first magnet and the carrier tape can be kept constant, thus permitting control of the force of attracting the component by the first magnet.

Moreover, the first magnet may be provided below bottom surfaces of the plurality of the component storage units fed to the feed region.

This consequently attracts all the components of the component storage units in the feed region to one side ends of the component storage units for alignment with high probability, which can therefore further reduce the absorption dislocation.

Moreover, a front end part of the first magnet in the feed direction may be provided below a portion occupying one fourth of an area of the bottom surface.

This consequently suppresses failure to perform the component absorption by the absorbing nozzle due to a too strong force of attracting the component of the component storage unit at the component take-out position by the first magnet.

Moreover, a carrier tape feeding method is a method of feeding in a tape feeder a carrier tape including a plurality of component storage units of a rectangular shape provided at predetermined intervals in a feed direction, and attracts a component of the component storage unit fed to a feed region in the tape feeder to one side of a bottom surface of the component storage unit in a width direction and towards back in the feed direction.

This consequently can reduce the absorption dislocation.

According to the invention, the absorption dislocation can be reduced, and thus cavity variation can be absorbed and the component take-out positions can be aligned to stabilize a component absorption rate and mounting accuracy.

FURTHER INFORMATION ABOUT TECHNICAL BACKGROUND TO THIS APPLICATION

The disclosure of Japanese Patent Application No. 2010-009476 filed on Jan. 19, 2010 including specification, drawings and claims is incorporated herein by reference in its entirety.

The disclosure of PCT application No. PCT/JP2011/000253 filed on Jan. 19, 2011, including specification, drawings and claims is incorporated herein by reference in its entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects, advantages and features of the invention will become apparent from the following description thereof taken in conjunction with the accompanying drawings that illustrate a specific embodiment of the invention. In the Drawings:

FIG. 1 is a top view of a component mounting machine according to an embodiment of the present invention;

FIG. 2 is a perspective view of a tape feeder according to the embodiment;

FIG. 3 is a perspective view of a carrier tape according to the embodiment;

FIG. 4 is a perspective view of a pressing cover according to the embodiment;

FIG. 5 is a perspective view of a plate spring according to the embodiment;

FIG. 6 is a perspective view of a magnet according to the embodiment;

FIG. 7 is a plan view showing a positional relationship between the magnet and the carrier tape;

FIG. 8 is a plan view showing how positions of components in component storage units are changed by the magnet;

FIG. 9 is a sectional view showing how the positions of the components in the component storage units are changed by the magnet;

FIG. 10A is a diagram showing absorption dislocation in a width direction of samples fed successively;

FIG. 10B is a diagram showing absorption dislocation in a feed direction of the samples fed successively;

FIG. 10C is a diagram showing absorption dislocation in the width and feed directions of the samples fed successively;

FIG. 11A is a diagram showing absorption dislocation in the width direction of the samples fed successively;

FIG. 11B is a diagram showing absorption dislocation in the feed direction of the samples fed successively;

FIG. 11C is a diagram showing absorption dislocation in the width and feed directions of the samples fed successively;

FIG. 12A is a diagram showing absorption dislocation in the width direction of the samples fed successively;

FIG. 12B is a diagram showing absorption dislocation in the feed direction of the samples fed successively;

FIG. 12C is a diagram showing absorption differences in the width and feed directions of the samples fed successively;

FIG. 13A is a diagram showing absorption dislocation in the width direction of the samples fed successively;

FIG. 13B is a diagram showing absorption dislocation in the feed direction of the samples fed successively;

FIG. 13C is a diagram showing absorption differences in the width and feed directions of the samples fed successively;

FIG. 14 is a perspective view of a magnet of Comparative Example 1 of the embodiment;

FIG. 15 illustrates a plan view and a sectional view showing how positions of the components in the component storage units are changed by the magnet;

FIG. 16 is a perspective view of a magnet of Comparative Example 2 of the embodiment;

FIG. 17 are a plan view and a sectional view showing how position of the components in the component storage units is changed by the magnet;

FIG. 18A is a diagram showing how the positions of the components in the component storage units are changed by vibration;

FIG. 18B is a diagram showing how the positions of the components in the component storage units are changed by vibration;

FIG. 18C is a diagram showing how the positions of the components in the component storage units are changed by weights of the components;

FIG. 18D is a sectional view showing configuration of an LED; and

FIG. 19 is a diagram showing correlation between a gap size of the component storage unit and an absorption error.

 DESCRIPTION OF THE PREFERRED EMBODIMENT

Hereinafter, a tape feeder and a carrier tape feeding method using the tape feeder according to an embodiment of the present invention will be described, with reference to the accompanying drawings.

FIG. 1 is a top view of a component mounting machine of this embodiment.

This component mounting machine includes: a base 100, a conveyance path 101, a component supply unit 103, a mounting head 105, a recognition camera 106, an XY robot 107, a waste tray 108, and a nozzle station 109.

The conveyance path 101 is disposed at a central part of the base 100, and conveys a substrate 104 to position it.

The component supply unit 103 has a plurality of tape feeders 102 arranged in parallel to each other, and supplies a plurality of kinds of components.

The mounting head 105 takes out the component from the component supply unit 103 and transfers and mounts it onto the substrate 104.

The recognition camera 106 recognizes the component absorbed to an absorbing nozzle of the mounting head 105 from the bottom of the component.

The XY robot 107 moves the mounting head 105 in an XY direction.

To the waste tray 108, the component is wasted.

The nozzle station 109 holds the absorbing nozzle of the mounting head 105.

FIG. 2 is a perspective view of the tape feeder 102.

The tape feeder 102 includes: a main body frame 120, a reel side plate 121, a supply reel 122, a feed roller 123, a ratchet 124, a feed lever 126, a tension spring 126a, a take-up reel 129, and a pressing cover 130.

The supply reel 122 is rotatably fitted to the reel side plate 121 coupled to the main body frame 120, and is wound with a carrier tape 122a holding the components.

The feed roller 123 pitch-feeds the carrier tape 122a pulled out from the supply reel 122.

The ratchet 124 rotates the feed roller 123.

The feed lever 126 rotates the ratchet 124 through fixed degrees by a link 125.

The take-up reel 129 takes up a cover tape 122b detached from the carrier tape 122a.

In the tape feeder 102 having the structure described above, the feed lever 126 is moved in an Y1 direction by a motor, an air cylinder, or the like to thereby rotate the ratchet 124 through the fixed degrees. Then in conjunction with the ratchet 124, the feed roller 123 rotates by a roller pitch. This feeds the carrier tape 122a by a component pitch defined as a space between the two adjacent components (component storage units). Then a force of pressing-out to the feed lever 126 is released, and the feed lever 126 returns in an Y2 direction, that is, to its original position by a bias force of the tension spring 126a. Repeating such a series of operations discharges the used carrier tape 122a to outside of the tape feeder 102. Note that the feed roller 123 may be rotated for the tape-feed of the carrier tape 122a by the motor without the aid of the feed lever 126, and that the take-up reel 129 may be wound by a motor different from the motor for rotating the feed roller 123. For example, in a case where the roller pitch is 2 mm and the component pitch is 2 mm, to feed the carrier tape 122a by the component pitch, the feed lever 126 is moved once. Note that the component pitch and the roller pitch do not have to be equal to each other.

FIG. 3 is a perspective view of the carrier tape 122a.

The carrier tape 122a includes: a base material tape 122c and the cover tape 122b. The carrier tape 122a is supplied to the user in a taped state in which the carrier tape 122a is wound around the supply reel 122 a predetermined number of times.

The base material tape 122c includes a plurality of rectangular component storage units (concave parts) 141 which are provided in a feed direction of the carrier tape 122a successively at predetermined intervals and which store components 140 of one chip type.

The cover tape 122b is attached to a top surface of the base material tape 122c so as to cover openings of the component storage units 141, thereby packing the components 140.

FIG. 4 is a perspective view of the pressing cover 130.

The pressing cover 130 has a shutter 127 and a slit 128, and is fitted to the main body frame 120 in a manner such that the shutter 127 is located above the ratchet 124.

Upon take-out of the component 140, the shutter 127 opens to expose, from the top, the component 140 of the component storage unit 141 below the shutter 127. The absorbing nozzle of the mounting head 105 absorbs the exposed component 140 to take it out.

The slit 128 functions as a cover tape detaching unit, and detaches the cover tape 122b from the carrier tape 122a in front of the shutter 127.

The tape feeder 102 includes below the pressing cover 130 a plate spring 160 as an elastic member as shown in a perspective view of FIG. 5. On a top part of the plate spring 160, the fed carrier tape 122a is placed whereby bottom surfaces of the component storage units 141 are supported. The plate spring 160 can absorb a force received by the component 140 and the carrier tape 122a from the absorbing nozzle upon the take-out of the component 140.

To a bottom surface opposite to the top surface of the plate spring 160 where the tape feeder 102 thereabove is placed, a magnet 150 of an L-shaped, plate-like form as shown in a perspective view of FIG. 6 is attached. The magnet 150 is formed by integrating a first magnet 151 arranged along the feed direction of the carrier tape 122a and a second magnet 152 arranged along a width direction orthogonal to the feed direction.

The first magnet 151 and the second magnet 152 are formed of an elastic body for the purpose of absorbing the force received by the component 140 and the carrier tape 122a from the absorbing nozzle upon the take-out of the component 140 by the absorbing nozzle.

Here, the magnet 150 is, for example, an isotropic Ba ferrite magnet, and a length of the first magnet 151 (a in FIG. 6) is, for example, 11.5 mm, a width of the first magnet 151 (b in FIG. 6) is, for example, 1.15 mm, and a length of the second magnet 152 (c in FIG. 6) is, for example, 1.15 mm.

Hereinafter, a region provided with the pressing cover 130 for taking out the component 140 located therebelow, specifically, a region above the plate spring 160, and more specifically, a region including the component storage unit 141 below the shutter 127 and, for example, the three preceding component storage units 141 (in front of the component storage unit 141 below the shutter 127 in the feed direction) is defined as a component take-out region that is a feed region of the tape feeder 102.

FIG. 7 is a plan view showing a positional relationship between the magnet 150 and the carrier tape 122a.

The first magnet 151 is provided below the bottom surfaces of the component storage units 141 fed to the feed region so as to extend in the feed direction below one side of the bottom surfaces of the component storage units 141 in the width direction, and attracts the components 140 of the component storage units 141 fed to the feed region to one side in the width direction and towards bottom.

Here, the first magnet 151 is provided below only half the bottom surfaces of the component storage units 141 in the feed region in parallel to the feed direction so as to cover only half of areas of the bottom surfaces of the component storage units 141. Moreover, the first magnet 151 is located below the bottom surfaces of the three component storage units 141 including the component storage unit 141 at a component take-out position. Further, a front end part of the first magnet 151 in the feed direction is provided below a portion occupying one-fourth of the area of the bottom surface of the component storage unit 141 in the feed region. This prevents failure to absorb the component 140 by the absorbing nozzle upon the take-out of the component 140 due to a too strong force of attracting the component 140 at the component take-out position by the first magnet 151.

Moreover, since the first magnet 151 attracts the components 140 of the component storage units 141 in the feed region to one side in the width direction and towards the bottom, great magnetic flux density of the first magnet 151 results in standing of the components 140 at the component storage units 141. Especially in a case where the component 140 is a tiny component and a case where the component 140 is of a dice-like shape, such standing of the component 140 is likely to occur. Therefore, it is preferable that the one having a surface maximum magnetic flux density of 50 mT or below, for example, approximately 40 mT be used as the first magnet 151.

The second magnet 152 is provided at the back in the feed direction with respect to the first magnet 151 below the bottom surfaces of the component storage units 141 in the feed region, and attracts the components 140 of the component storage units 141 fed to the feed region to the back in the feed direction and towards the bottom.

Here, the second magnet 152 is so provided as to be separated from the component storage unit 141 at the component take-out position by a distance sandwiching the two component storage units 141. Therefore, this prevents the standing of the component 140 at the component take-out position and failure to absorb the component 140 by the absorbing nozzle upon the take-out of the component 140 due to a too strong force of attracting the component 140 by the second magnet 152.

Since the second magnet 152 attracts the components 140 of the component storage units 141 towards the feed direction and towards the bottom in the feed region, great magnetic flux density of the second magnet 152 results in standing of the components 140 at the component storage units 141. Therefore, it is preferable that the one having a maximum surface magnetic flux density of 50 mT or below, for example, approximately 40 mT be used.

Plan views of FIG. 8 and sectional views of FIG. 9 show how positions of the components 140 in the component storage units 141 are changed by the magnet 150.

First, as shown in FIGS. 8A and 9A, the carrier tape 122a is fed in the feed direction by the component pitch, whereby one of the component storage units 141 is fed to the feed region. The magnet 150 is located below the component storage unit 141 fed to the feed region, and the component 140 of the component storage unit 141 above the magnet 150 is attracted to the bottom of the component storage unit 141.

Next, as shown in FIGS. 8B and 9B, the carrier tape 122a is further fed in the feed direction by the component pitch, whereby one of the other component storage units 141 is fed to the feed region. The component 140 of the component storage unit 141 already fed to the feed region is attracted towards the feed direction and the width direction by the magnet 150, and moves to ends of the component storage unit 141 in the feed direction and the width direction, that is, a corner of the component storage unit 141.

Next, as shown in FIGS. 8C and 9C, the carrier tape 122a is further fed in the feed direction by the component pitch, whereby one of the other component storage units 141 is further fed to the feed region. The components 140 moved to the corner of the component storage units 141 are continuously attracted towards the feed direction and the width direction by the magnet 150, thereby maintaining their positions.

Finally, as shown in FIGS. 8D and 9D, the carrier tape 122a is further fed in the feed direction by the component pitch, whereby one of the other component storage units 141 is further fed to the feed region and also one of the component storage units 141 in the feed region is fed to the component take-out position. Then the component 140 at the component take-out position is taken out by the absorbing nozzle. All the components 140 fed to the component take-out position are located at the corners of the component storage units 141 in a fixed manner by the magnet 150; therefore, an absorption position of the component 140 at the component take-out position is kept constant.

FIGS. 10A to 13C are diagrams illustrating that absorption dislocation can be reduced by the tape feeder 102. FIGS. 10A to 10C and 12A to 12C show absorption dislocation change when a magnet is provided below the entire bottom surfaces of the component storage units 141 and the plurality of components 140 are taken out successively. FIGS. 11A to 11C and FIGS. 13A to 13C show absorption dislocation change when the magnet 150 in a mode of FIG. 7 is provided and the plurality of components 140 are taken out successively.

FIGS. 10A to 11C show the absorption dislocation when the component 140 is a capacitor, and FIGS. 12A to 13C show the absorption dislocation when the component 140 is a resistor. Moreover, in FIGS. 10A, 11A, 12A, and 13A, a horizontal axis indicates sample numbers and a vertical axis indicates the absorption dislocation (dX) in the width direction. In FIGS. 10B, 11B, 12B, and 13B, a horizontal axis indicates the sample numbers and a vertical axis indicates the absorption dislocation (dY) in the feed direction. In FIGS. 10C, 11C, 12C, and 13C, a horizontal axis indicates the absorption dislocation in the width direction and a vertical axis indicates the absorption dislocation in the feed direction.

Making comparison between FIGS. 10A to 10C and FIGS. 11A to 11C and between FIGS. 12A to 12C and FIGS. 13A to 13C proves that the magnet 150 of FIG. 7 reduces the absorption dislocation in the width direction and the feed direction. Moreover, in FIGS. 10B and 12B, the absorption dislocation dramatically changes near the sample number 390 in particular due to a characteristic change of the tape feeder 102, but in FIGS. 11B and 13B, there is no such a change in the absorption dislocation due to the characteristic change of the tape feeder 102. Therefore, it is proved that the magnet 150 of FIG. 7 suppresses the absorption dislocation due to the characteristic change of the tape feeder 102. Further, making comparison between FIGS. 11A to 11C and FIGS. 13A to 13C shows no great difference in the absorption dislocation. Therefore, it is proved that the magnet 150 of FIG. 7 can reduce the absorption dislocation of the component 140 as the resistor less susceptible to a magnetic force than the component 140 as the capacitor and can reduce the absorption dislocation for various kinds of components 140.

As described above, the tape feeder 102 of this embodiment includes the first magnet 151 below one side of the bottom surfaces of the component storage units 141 in the feed region, and includes the second magnet 152 of an island shape at the back in the feed direction with respect to the first magnet 151. Therefore, the components 140 of the component storage units 141 in the feed region are attracted by the first magnet 151 to side ends of the component storage units 141 in the width direction and simultaneously attracted by the second magnet 152 to rear ends of the component storage units 141 in the feed direction by use of a force of feeding the carrier tape 122a. As a result, all the components 140 of the component storage units 141 are pulled to the ends of the component storage units 141 for alignment, which can therefore reduce the absorption dislocation.

Moreover, with the tape feeder 102 of this embodiment, the first magnet 151 and the second magnet 152 are provided below the bottom surfaces of the component storage units 141 in the feed region. Therefore, the components 140 of the component storage units 141 in the feed region are attracted towards the bottom of the component storage units 141 by the first magnet 151 and the second magnet 152. This consequently prevents the components 140 of the component storage units 141 to pop out of the component storage units 141 and stand in the feed region.

Moreover, with the tape feeder 102 of this embodiment, the first magnet 151 is provided below half of the bottom surfaces of the component storage units 141. This consequently can prevent the components 140 of the component storage units 141 from being forcefully attracted to stand by the first magnet 151.

Comparative Example 1

Hereinafter, a magnet 150 according to Comparative Example 1 of this embodiment will be described.

FIG. 14 is a perspective view of the magnet 150 according to this Comparative Example.

The magnet 150 according to this comparative example is different from the magnet 150 of FIG. 6 in that the magnet 150 according to this comparative example has a width in the width direction increasingly narrowing towards the feed direction and thus has a triangular shape instead of an L-shape.

A plan view and a sectional view of FIGS. 15A and 15B show how the positions of the components 140 in the component storage units 141 are changed by the magnet 150 according to this comparative example.

The components 140 fed to the feed region are also attracted towards the feed direction and the width direction in the feed region by the magnet 150 according to this comparative example, and thereby move to the ends of the component storage units 141 in the feed direction and the width direction. However, the triangular shape of the magnet 150 causes distortion of the magnet, and thus the components 140 in the feed region turn to tilt in the feed direction and the width direction. On the contrary, for the L-shaped magnet 150 of FIG. 6, such turning of the components 140 does not occur, which can therefore reduce the absorption dislocation.

Comparative Example 2

Hereinafter, a magnet 150 according to Comparative Example 2 of this embodiment will be described.

FIG. 16 is a perspective view of the magnet 150 according to this comparative example.

The magnet 150 according to this comparative example differs from the magnet 150 of FIG. 6 in that the magnet 150 according to this comparative example is provided with a portion extending in the width direction not only at the rear end in the feed direction but also at the front end, and the magnet 150 according to this comparative example is not L-shaped but U-shaped.

A plan view and a sectional view of FIGS. 17A and 17B show how the positions of the components 140 in the component storage units 141 are changed by the magnet 150 according to this comparative example.

The components 140 fed to the feed region are also attracted towards the feed and the width direction in the feed region by the magnet 150 according to this comparative example, and thereby move to the ends of the component storage units 141 in the feed direction and the width direction. However, since the component 140 approaching the component take-out position is attracted to the front in the feed direction by the U-shape of the magnet 150, the position of the component 140 at the component take-out position is not fixed at the end in the feed direction. On the contrary, for the L-shaped magnet 150 of FIG. 6, the position of the component 140 after the movement is fixed, which can therefore reduce the absorption dislocation.

The tape feeder and the carrier tape feeding method using the tape feeder according to the invention have been described above with reference to the embodiment, although the invention is not limited to this embodiment. Various modifications thought by those skilled in the art within a range not departing from the spirits of the invention are included in a range of the invention. Moreover, any of the components in the embodiment may be combined together within the range not departing from the spirits of the invention.

For example, in the embodiment described above, the magnet 150 is L-shaped. However, the magnet 150 is not limited to this as long as it generates a magnetic force of attracting the components 140 in the feed region to the ends of the component storage units 141. For example, the magnet 150 may be formed of the first magnet 151 and the second magnet 152 separated from each other.

Moreover, in the embodiment described above, the second magnet 152 is so provided as to be separated from the component storage unit 141 at the component take-out position by the distance sandwiching the two component storage units 141, although not the magnet 152 is limited to this as long as it can is separated by a distance that does not impede the component take-out by the absorbing nozzle with consideration given to, for example, a magnetic force of the second magnet 152 and the component pitch. For example, in a case where the magnetic force of the second magnet 152 is strong, the second magnet 152 may be provided below the component storage unit 141 next to the component storage unit 141 at the component take-out position. In a case where the magnetic force of the second magnet 152 is weak, the second magnet 152 may be so provided as to be separated from the component storage unit 141 at the component take-out position by a distance sandwiching the three or more component storage units 141.

Moreover, in the embodiment described above, the first magnet 151 is provided below the bottom surfaces of the component storage units 141 in the feed region so as to cover the half areas of the bottom surfaces of the component storage units 141. However, the first magnet 151 may be provided below the bottom surfaces of the component storage units 141 in the feed region so as to cover not all but only part of the bottom surfaces of the component storage units 141 in the width direction, without being limited to the half areas.

Moreover, in the embodiment described above, the first magnet 151 is provided below the bottom surfaces of the three component storage units 141 fed to the feed region, although the number is not limited to 3 as long as the first magnet 151 is provided below the bottom surfaces of the plurality of component storage units 141 fed to the feed region.

Moreover, in the embodiment described above, the first magnet 151 is provided. However, the first magnet 151 is not limiting as long as the tape feeder has a first magnetic force region which is provided below the bottom surfaces of the component storage units 141 fed to the feed region so as to extend in the feed direction below one side of the bottom surfaces in the width direction and which attracts the components of the component storage units 141 fed to the feed region to one side in the width direction. For example, in the embodiment described above, the first magnetic force region is formed of one first magnet 151 but may be formed of a plurality of magnets.

Moreover, in the embodiment described above, the second magnet 152 is provided. However, the second magnet 152 is not limiting as long as the tape feeder has a second magnetic force region which is provided at the back in the feed direction with respect to the first magnetic force region below the bottom surfaces of the component storage units 141 fed to the feed region and which attracts the components of the component storage units 141 fed to the feed region to the back in the feed direction. For example, in the embodiment described above, the second magnetic force region is formed of one second magnet 152 but may be formed of a plurality of magnets.

Moreover, in the embodiment described above, vibration is added to the tape feeder before the components 140 are attracted to the ends of the component storage units 141 by the magnet 150. Alternatively, the tape feeder may be tilted to thereby move the components 140 to the ends of the component storage units 141.

For example, as shown in FIG. 18A, the components 140 may be moved to the ends of the component storage units 141 by, for example, a vibrator and a spring vibrating in the width direction of the tape feeder. Moreover, as shown in FIG. 18B, the components 140 may be moved to the ends of the component storage units 141 by, for example, a vibrator and a spring vibrating in a direction through 45 degrees with respect to the feed direction of the tape feeder. Further, as shown in FIG. 18C, a regulating roller 170 for feeding the tape feeder may be tilted through, for example, 25 degrees to move the components 140 to the ends of the component storage units 141 by weights of the components 140.

Configuration of FIGS. 18A to 18C is effective for, for example, the component 140 like an LED (Light Emitting Diode) shown in a sectional view of FIG. 18D. The reasons are as follows. The resistor and the capacitor use Ni (nickel) plating for internal and external electrodes and have some members formed of a magnetic body. On the contrary, in an LED chip, for example, a lead frame is formed of a material containing a large quantity of gold or silver with small current loss, an electrode 180 is also formed of not nickel-plating but gold-flash plating, and these members are formed of a material hardly or less susceptible to the magnetic force. Moreover, the electrode 180 and a component body 181 formed on the same bottom surface of the LED are formed of different materials, for example, gold-flash plating and glass epoxy region; therefore, they have different surface slip coefficients, and thus are hard to slip in the component storage unit 141. Moreover, an area in which the component body 180 and the component storage unit 141 are in contact with each other is large, resulting in difficulty in slipping in the component storage unit 141. Furthermore, the electrode 180 and the component body 181 formed on the same bottom surface have unevenness on their front surfaces, thus frequently providing configuration such that slipping in the component storage unit 141 is difficult.

Although only some exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention.

INDUSTRIAL APPLICABILITY

The present invention can be used for a tape feeder and a carrier tape feeding method using the tape feeder, and can be used especially for a component mounting machine, etc.

Claims

1. A tape feeder feeding a carrier tape including a plurality of component storage units of a rectangular shape provided at predetermined intervals in a feed direction, the tape feeder comprising:

a first magnet provided below a bottom surface of said component storage unit fed to a feed region in a manner such as to extend in the feed direction below one side of the bottom surface in a width direction, said first magnet attracting a component of said component storage unit fed to the feed region to one side in the width direction; and
a second magnet provided at back in the feed direction with respect to said first magnet below the bottom surface of said component storage unit fed to the feed region, said second magnet attracting the component of said component storage unit fed to the feed region towards the back in the feed direction,
wherein said first magnet and said second magnet form an L-shaped magnet.

2. The tape feeder according to claim 1,

wherein said first magnet and said second magnet are integrated together.

3. A tape feeder feeding a carrier tape including a plurality of component storage units of a rectangular shape provided at predetermined intervals in a feed direction, said tape feeder comprising:

a first magnet provided below a bottom surface of said component storage unit fed to a feed region so as to extend in the feed direction below one side of the bottom surface in a width direction, said first magnet attracting a component of the component storage unit fed to the feed region to one side in the width direction; and
a second magnet provided at back in the feed direction with respect to said first magnet below the bottom surface of the component storage unit fed to the feed region, said second magnet attracting the component of the component storage unit fed to the feed region towards the back in the feed direction,
wherein a front end part of said first magnet in the feed direction is provided below a portion occupying one-fourth of an area of the bottom surface.

4. The tape feeder according to claim 3,

wherein said first magnet and said second magnet are integrated together to form an L-shaped magnet.

5. The tape feeder according to claim 1,

wherein said first magnet is provided below half of the bottom surface.

6. The tape feeder according to claim 1,

wherein said first magnet is formed of an elastic body.

7. The tape feeder according to claim 1, further comprising

an elastic member of a plate-like shape supporting the bottom surface of the component storage unit fed to the feed region,
wherein said first magnet is attached to a surface of said elastic member opposite to a side on which the bottom surface is placed.

8. The tape feeder according to claim 1,

wherein said first magnet is provided below bottom surfaces of the plurality of said component storage units fed to the feed region.

9. The tape feeder according to claim 1,

wherein a front end part of said first magnet in the feed direction is provided below a portion occupying one fourth of an area of the bottom surface.

10. A carrier tape feeding method of feeding in a tape feeder a carrier tape including a plurality of component storage units of a rectangular shape provided at predetermined intervals in a feed direction,

attracting, by a first magnet and a second magnet forming an L-shaped magnet, a component of the component storage unit fed to a feed region in the tape feeder to one side of a bottom surface of the component storage unit in a width direction and towards back in the feed direction,
wherein the first magnet is provided below the bottom surface of the component storage unit fed to the feed region so as to extend in the feed direction below one side of the bottom surface in the width direction, and attracts the component of the component storage unit fed to the feed region to one side in the width direction, and
the second magnet is provided at back in the feed direction with respect to the first magnet below the bottom surface of the component storage unit fed to the feed region, and attracts the component of the component storage unit fed to the feed region towards the back in the feed direction.

11. The tape feeder according to claim 1,

wherein said first magnet and said second magnet are integrated together.

12. A carrier tape feeding method of feeding in a tape feeder a carrier tape including a plurality of component storage units of a rectangular shape provided at predetermined intervals in a feed direction, a front end part of the first magnet in the feed direction is provided below a portion occupying one fourth of an area of the bottom surface.

attracting, by a first magnet and a second magnet forming an L-shaped magnet, a component of the component storage unit fed to a feed region towards one side of a bottom surface of the component storage unit in a width direction and towards back in the feed direction,
wherein the first magnet is provided below the bottom surface of the component storage unit fed to the feed region so as to extend in the feed direction below one side of the bottom surface in the width direction, and attracts the component of the component storage unit fed to the feed region to one side in the width direction,
the second magnet is provided at back in the feed direction with respect to the first magnet below the bottom surface of the component storage unit fed to the feed region, and attracts the component of the component storage unit fed to the feed region towards the back in the feed direction, and
Patent History
Publication number: 20120000958
Type: Application
Filed: Sep 6, 2011
Publication Date: Jan 5, 2012
Inventors: Masanori IKEDA (Yamanashi), Satoshi Furuichi (Yamanashi), Masahiro Taniguchi (Yamanashi), Yousuke Hassaku (Yamanashi)
Application Number: 13/225,772
Classifications
Current U.S. Class: Processes (226/1); By Orbitally Traveling Material-engaging Surface(s) (226/168)
International Classification: B65H 20/02 (20060101);