Load port system for handling component carriers

Abstract

To provide a load port system for safely handling component carriers between a container and a processing machine. The load port system 100 includes a load port unit 110 having a load port body 111 and a door manipulator 112, and a container 120 having a storage volume vs for storing a component carrier, the container having a housing with an opening selectively closable by a container door 121. The container door is configured to be movable along a translatory direction relative to the housing, and the load port unit has a docking section 113 for placing the container. When the door is placed in the docking section, the door is configured to be selectively coupled to the door manipulator, and the door manipulator is movably coupled to the load port body for moving the container door in the translatory direction.

Description

[Technical field]

[0001] The present invention relates to a load port system for handling component carriers. [Background technology]

[0002] In the context of increasing product functionality of component carriers comprising one or more components and of such components becoming smaller, as well as an increasing number of components connected to component carriers such as printed circuit boards, increasingly more powerful array-like components or packages are utilized having several components, which have multiple contacts or connections with an ever-decreasing spacing between these contacts. In particular, component carriers should be mechanically robust and electrically reliable so as to be able to operate under harsh conditions. More and more functions are being integrated into the component carriers.

[0003] Therefore, the method of manufacturing the respective component carrier should be very precise and at the same time very efficient. In particular, it is important for the manufacture of the component carriers that the component carriers can be transported between all processing stages in a fast and safe manner without any damage during the transport. Damage to the semi-finished component carriers can be caused, for example, by foreign objects (FM) that scratch along the surface of the respective component carrier to be transported. For example, FM particles can be generated during handling of the component carriers, for example, if the component carrier scratches along the supporting surface. FM particles are also present in the surrounding environment (i.e. dust) and can adhere to the component carrier surface due to gravitational or electrostatic attraction.

[0004] When the component carriers are transported to the respective processing machines, it is important that easy access to the storage volume of the container is provided, for example to gently remove the component carrier from the container, in particular it is important that there are no particles between the container and the further processing machine that could contaminate the component carrier.

[0005] It may therefore be necessary to provide a safe handling system between the container and the processing machine. Summary of the Invention

[0006] According to an exemplary embodiment of the present invention, a load port system for handling a component carrier is provided. The load port system includes a load port unit having a load port body and a door manipulator, and a container having a storage volume for storing the component carrier, the container having a housing with an opening selectively closable by a container door of the container. The container door is configured to be movable along a translatory direction (e.g., translatory linear movement along a straight line or curve) relative to the housing, and the load port unit has a docking section for placing the container. The door is configured to be selectively coupled to the door manipulator when placed in the docking section, and the door manipulator is movably coupled to the load port body for moving the container door in the translatory direction.

[0007] The component carrier, or a panel including several component carriers, can be temporarily stored in the container described above. The component carrier may comprise a stack of at least one electrically insulating layer structure and at least one electrically conductive layer structure. For example, the component carrier may in particular be a laminate of the above-mentioned electrically insulating and conductive layer structures formed by applying mechanical pressure, supported by thermal energy if desired. The stack may provide a plate-shaped component carrier that can be very thin and compact, nevertheless offering a large mounting surface for further components. The term "layer structure" may in particular denote a continuous layer, a patterned layer or a plurality of discontinuous islands in a common plane. In the context of the present invention, the term "layer structure" may be a single layer or a multi-layer assembly.

[0008] In one embodiment, the component carrier is plate-shaped. This contributes to a compact design, which nevertheless provides a large base for mounting components thereon. Furthermore, due to their thinness, particularly bare dies, as examples of embedded electronic components, can be conveniently embedded in thin plates such as printed circuit boards. In one embodiment, the component carrier is configured as one of the group consisting of printed circuit boards, substrates (particularly IC substrates) and interposers.

[0009] The container has a storage volume defining an interior volume of the container housing in which the component carriers can be temporarily stored. The container may have an opening that can be selectively closed by a respective container door to provide access to the interior volume.

[0010] The container can further be transported between two desired locations, in particular between two processing machines. The container may therefore be handled by a trolley or have wheels for moving between the processing machines and the load port units, respectively.

[0011] The container door is configured to be opened and closed along a linear direction. For example, a magnetic element that can be magnetically coupled to a corresponding frame element of the housing can hold the container door to the container body. In particular, the door may not have any hinges so that the door can be completely removed from the container when the opening force exceeds the magnetic coupling force applied by the magnetic element.

[0012] The load port unit is arranged between the container and the processing machine. The load port unit ensures that the component carrier is not contaminated by, for example, the ambient air surrounding the load port system. Thus, an opening of the container may be temporarily sealed in the load port unit so that the component carrier can be removed from the container and further handled to the processing machine.

[0013] The load port unit comprises a load port body having a respective load port volume, which may provide clean room conditions so that the component carriers can be handled without contamination within the load port body.

[0014] The container is placed on the docking section to provide a sealed connection between the container and the load port unit. The docking section may include a docking plate on which the container may be placed. For example, a trolley transporting the container may place the container in the correct position on the docking section. Additionally or alternatively, the docking section may include adjustment means such as a further manipulator or conveyor belt to position the container in the correct position relative to the load port body.

[0015] The load port unit further comprises a door manipulator movably coupled to the load port body, the door manipulator including a clamp or gripping means for coupling to the container door, and the door manipulator is further coupled to the load port body such that the door manipulator is movable along a translational direction, for example vertically or horizontally.

[0016] Therefore, according to the approach of the present invention, by providing the container with the container door described above which is movable along a translatory direction, a door manipulator can be coupled to the container door and in a next step may move together with the container door along the translatory direction to remove the container door from the container body. When the container door has been removed from the container body by the door manipulator, the storage volume of the container is sealedly connected to the load port volume so that the component carrier can be moved between the load port body and the container without being contaminated.

[0017] According to an exemplary embodiment, the load port body has a load port volume for storing the component carrier, and the load port unit has a component carrier handling unit for handling the component carrier between the container and the load port volume. The manipulator may for example include a clamping unit or a suction cup for handling the component carrier.

[0018] According to a further exemplary embodiment, the load port unit comprises a filter unit for filtering air in the load port volume. The filter unit may include a respective fan element for introducing clean air into the load port volume.

[0019] According to a further exemplary embodiment, the docking section is movable to adjust the position of the container relative to the door manipulator. In particular, the docking section may be horizontally and / or vertically movable relative to the load port body to adjust the container to a desired position relative to the load port body and the door manipulator, respectively.

[0020] According to a further exemplary embodiment, the load port unit comprises a sensor unit for detecting the position of the container on the dock. The sensor unit may comprise, for example, a camera or a light barrier for detecting the position of the container and, for example, also of the dock. In addition, the sensor unit may comprise physical contact elements adapted to be coupled to the respective position elements of the container. For example, the container has respective recesses into which the contact elements of the sensor unit may be inserted. If the contact elements are introduceable into the respective recesses, the correct position of the container relative to the load port body is identified. In addition, the contact elements may comprise a locking function. If the container is in the correct position, the contact elements lock the container, for example, such that further displacement of the container relative to the load port body is prevented. In addition, the sensor elements may be movable relative to the load port unit so that the sensor unit can be moved to the container after the container is placed on the dock.

[0021] According to a further exemplary embodiment, the container door comprises a handling element configured to be coupled to the door manipulator. The handling element may provide a handle in the form of a hook or a closed ring so that a respective gripping tool, such as a gripping fork or a gripping bracket of the door manipulator, can grip the handling element. After gripping the handling element, the door manipulator may move the door along a linear direction (vertical or horizontal) in order to open the container.

[0022] According to a further exemplary embodiment, the door manipulator has receiving holes for receiving the handling elements and for fixing the handling elements to the door manipulator, thus ensuring that the container is in the correct position relative to the load port body when the handling elements can be inserted into the respective receiving holes of the door manipulator.

[0023] According to a further exemplary embodiment, the door manipulator comprises a movable shutter element for selectively closing the load port volume, such that the storage volume of the container and the load port volume are connectable when the container door moves with the shutter element. The shutter element forms a sealed closure sealing the load port volume from the ambient air. The door manipulator may comprise a gripping tool for gripping a handling element of the container door. The shutter elements may have respective openings through which the handling elements are guided inside the load port body when the container is placed in the correct position. When the handling elements extend through the openings of the shutter elements, the door manipulator may move relative to the shutter element and grip the handling element of the container door. In a next step, the door manipulator may move along a vertical or horizontal direction and simultaneously move the container door and the shutter element such that the storage volume of the container and the load port volume are connected.

[0024] According to a further exemplary embodiment, the load port system comprises a processing machine for processing the component carriers, the load port unit having a further component carrier handling unit for handling the component carrier between the processing machine and the load port volume. The processing machine can for example be a laser drilling machine for drilling holes in the component carrier. Furthermore, the processing machine can be a machine for chemical treatment of the component carrier. The further manipulator can for example comprise a clamping unit or a suction cup for handling the component carrier.

[0025] Further, a method of handling a component carrier by the above described load port system is also presented. First, the trolley moves the container to the docking section. Then, the docking section may lift the container in order to release it from the trolley. In a further step, the docking section is moved to a position such that the container is in a predefined position relative to the door manipulator. In the predefined position, the handling elements of the container door protrude through respective openings of the shutter elements closing the openings of the load port body. Then, after the predefined position is determined by the sensor unit, the door manipulator lifts the container door together with the shutter elements such that the storage volume of the container and the load port volume of the load port body are connected.

[0026] The above-defined and further aspects of the invention are apparent from and will be elucidated with reference to the example embodiments described hereinafter. [Brief description of the drawings]

[0027] [Figure 1] 1 is a schematic diagram of a load port system illustrating coupling of a container having a component carrier to a load port unit according to an exemplary embodiment; [Diagram 2] 1 is a schematic diagram of a load port system illustrating coupling of a container having a component carrier to a load port unit according to an exemplary embodiment; [Diagram 3] 1 is a schematic diagram of a load port system illustrating coupling of a container having a component carrier to a load port unit according to an exemplary embodiment; [Figure 4] 1 is a schematic diagram of a load port system illustrating coupling of a container having a component carrier to a load port unit according to an exemplary embodiment; [Diagram 5]1 is a schematic diagram of a load port system illustrating coupling of a container having a component carrier to a load port unit according to an exemplary embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] What is shown in the drawings is schematic: in different drawings, similar or identical elements are given the same reference signs.

[0029] FIG. 1 shows a schematic diagram of a load port system 100 illustrating coupling of a container 120 having a component carrier 501 (see FIG. 5) to a load port unit 110 according to an exemplary embodiment. The load port unit 110 includes a load port body 111 and a door manipulator 112. The load port system 100 further includes a container 120 having a storage volume vs for storing the component carrier 501, the container 120 having a housing with an opening selectively closable by a container door 121 of the container 120. The container door 121 is configured to be movable along a translatory direction relative to the housing, and the load port unit 110 includes a docking section 113 for positioning the container 120. The door is configured to be selectively coupled to a door manipulator 112 when positioned at the docking section 113, the door manipulator 112 being movably coupled to the load port body 111 for moving the container door 121 in the translatory direction.

[0030] The container 120 has a storage volume vs that defines an interior volume of the housing of the container 120 in which a component carrier 501 can be temporarily stored. The container 120 has an opening that can be selectively closed by a respective container door 121 to provide access to the storage volume vs.

[0031] The container 120 can further be transported between two desired locations, in particular between two processing machines 503. The container may therefore be handled by a trolley 101 or may have wheels for moving between the processing machines 503 and the load port units 110, respectively.

[0032] The load port unit 110 comprises a load port body 111 having a respective load port volume vlp. The load port volume vlp may provide clean room conditions so that the component carriers 501 can be handled within the load port body 111 without contamination.

[0033] The docking station 113 includes a docking plate on which the container 120 is placed. For example, a trolley 101 carrying the container 120 places the container 120 in the correct position on the docking station 113.

[0034] The load port unit 110 has a filter unit 114 for filtering the air in the load port volume vlp. The filter unit 114 may include a respective fan element for transporting air into and / or out of the load port volume vlp. Thus, for example, clean air may be introduced into the load port volume vlp.

[0035] 2 shows that the docking unit 113 is movable to adjust the position of the container 120 relative to the door manipulator 112. Specifically, the docking unit 113 may be horizontally and / or vertically movable relative to the load port body 111 to adjust the container 120 to a desired position relative to the load port body 111 and the door manipulator 112, respectively. In FIG. 2, the trolley 101 moves the container 120 to the load port unit 110, which detects the arrival of the container 120. In the next step, the docking unit 113 lifts the container 120 to the desired position. The container 120 may slide close to the load port body 111.

[0036] The door manipulator 112 includes a moveable shutter element 116 for selectively closing the load port volume vlp such that the storage volume vs of the container 120 and the load port volume vlp are connectable when the container door 121 moves with the shutter element 116. The shutter element 116 forms a sealed closure.

[0037] The container door 121 includes a handling element 122 configured to be coupled to the door manipulator 112. The door manipulator 112 may include a gripping tool for gripping the handling element 122 of the container door 121. The shutter element 116 has a respective opening through which the handling element 122 is guided inside the load port body 111 when the container 120 is placed in the correct position. When the handling element 122 extends through the opening of the shutter element 116, the door manipulator 112 can move relative to the shutter element 116 and grip the handling element 122 of the container door 121. Thus, when the handling element 122 is insertable into the respective receiving hole of the door shutter element 116, it is ensured that the container 120 is in the correct position relative to the load port body 111.

[0038] 3, the container 120 is positioned on the docking section 113, with the handling element 122 extending through the opening in the shutter element 116. The door manipulator 112 secures the handling element 122.

[0039] The sensor unit 115 detects the position of the container 120 on the docking section 113. The sensor unit 115 may include physical contact elements adapted to be coupled to the respective position elements of the container 120. For example, the container 120 has respective recesses into which the contact elements of the sensor unit 115 may be inserted. When the contact elements are introduceable into the respective recesses, the correct position of the container relative to the load port body 111 is identified. In addition, the contact elements may have a locking function. When the container 120 is in the correct position, the contact elements lock the container 120, for example, such that further displacement of the container 120 relative to the load port body 111 is prevented.

[0040] 4 shows that the container door 121 is configured to be opened and closed along a translatory direction. In particular, the container door 121 may not have any hinges so that the container door 121 can be completely removed from the container 120. The handling element 122 may provide a hook or ring shaped handle so that a respective gripping tool, such as a gripping fork or a gripping bracket of the door manipulator 112, can grip the handling element. After gripping the handling element, the door manipulator may move the door along a translatory direction (vertical or horizontal) to open the container. In the stage shown in FIG. 4, the door manipulator 112 moves the container door 121 horizontally away from the container 120.

[0041] In the stage shown in FIG. 5, the door manipulator 112 moves along the vertical direction and simultaneously moves the container door 121 and the shutter element 116 so that the storage volume vs of the container and the load port volume vlp are connected.

[0042] The load port unit 110 is disposed between the container 120 and the processing machine 503. The load port unit 110 ensures that the component carrier 501 is not contaminated by, for example, the ambient air surrounding the load port system 100. Therefore, the opening of the container 120 is temporarily sealed by the load port unit 110 so that the component carrier 501 can be removed from the container 120 and further handled to the processing machine 503. In summary, by providing the container 120 with a container door 121 that is movable along a translatory direction, the door manipulator 112 can be coupled to the container door 121 and may move together with the container door 121 along the translatory direction in a next step to remove the container door 121 from the container body. When the container door 121 is removed from the container body by the door manipulator 112, the storage volume vs of the container 120 is sealedly connected to the load port volume vlp so that the component carrier 501 can be moved between the load port body 111 and the container 120 by the handling unit 502.

[0043] The load port system 100 further includes a processing machine 503 for processing the component carrier 501, and the component carrier handling unit 502 handles the component carrier 501 between the processing machine 503 and the load port volume vlp.

[0044] It should be noted that the term "comprising" does not exclude other elements or steps, and "a" or "an" do not exclude a plurality. Also, elements described in association with different embodiments may be combined.

[0045] It should also be noted that reference signs in the claims shall not be construed as limiting the scope of the claims.

[0046] The implementation of the invention is not limited to the preferred embodiment shown in the drawings and described above, instead many variations are possible that use the solutions shown and the principles according to the invention, even in the case of substantially different embodiments. [Explanation of symbols]

[0047] 100 Load Port System 101 Trolley 110 Load Port Unit 111 Load port body 112 Door Manipulator 113 Docking section 114 Filter unit 115 Sensor unit 116 Shutter Element 120 Container 121 Container Door 122 Handling Elements 501 Component Carrier 502 Handling Unit 503 Processing machine vs Storage volume vlp load port volume

Claims

1. 1. A load port system for handling a component carrier, comprising: a load port unit having a load port body and a door manipulator; a container having a storage volume for storing the component carrier; Equipped with the container has a housing having an opening selectively closeable by a container door of the container; the container door is configured to be movable along a translational direction relative to the housing; the load port unit has a docking section for placing the container, the container door is configured to be selectively coupled to the door manipulator when the container door is disposed in the docking section; The door manipulator is movably coupled to the load port body for moving the container door in a linear direction.

2. the load port body has a load port volume for storing the component carrier, The load port system of claim 1 , wherein the load port unit comprises a component carrier handling unit for handling the component carrier between the container and the load port volume.

3. The load port system of claim 2 , wherein the load port unit has an air exchange system for exchanging air from the surroundings with air from the load port volume.

4. The load port system of claim 3 , wherein the air exchange system comprises a filter unit for filtering air within the load port volume.

5. The load port system according to claim 1 , wherein the docking section is movable to adjust the position of the container relative to the door manipulator.

6. The load port system according to claim 1 , wherein the load port unit has a sensor unit that detects a position of the container on the docking section.

7. The load port system of claim 1 , wherein the container door has a handling element configured to be coupled to the door manipulator.

8. The load port system according to claim 7 , wherein the door manipulator has an accommodation hole for accommodating the handling element and for fixing the handling element to the door manipulator.

9. 3. The load port system of claim 2, wherein the door manipulator includes a movable shutter element that selectively closes the load port volume, such that when the container door moves with the movable shutter element, the storage volume of the container and the load port volume are connectable.

10. The load port system includes: The component carrier further includes a processing machine for processing the component carrier, 10. The load port system according to claim 1, wherein the load port unit comprises a further component carrier handling unit for handling the component carrier between the processing machine and the load port volume.

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