Component and solder preform placement device and method of placement

Claim 3

The method of claim 1 wherein said item holder comprises a thin sheet having a plurality of holes therein, each smaller than a dimension of one of said items, and wherein said step of detachably securing said items to said item holder comprises drawing a vacuum through the holes in said item holder.

Claim 4

The method of claim 1 wherein said step of providing a kinetic cloud comprises the step of imparting sufficient kinetic energy to said items to project a plurality of said discrete items randomly toward and adjacent said item holder.

Claim 5

The method of claim 3 wherein said step of randomly projecting discrete items comprises the step of positioning a plurality of items on a vibratory membrane and vibrating the membrane to project the items toward said part holder.

Claim 6

The method of claim 4 wherein said item holder comprises a thin sheet having a plurality of holes therein, each smaller than a dimension of one of said items, wherein said step of detachably securing said items to said item holder comprises drawing a vacuum through the holes in said item holder and wherein said step of positioning said item holder adjacent said substrate comprises the steps of moving said item holder toward said substrate so as to register the pattern of the item holder with the substrate pattern while maintaining said vacuum to detachably secure items to the item holder, and terminating said vacuum when the items are at said predetermined substrate pattern.

Claim 7

The method of claim 2 wherein said step of drawing vacuum comprises the step of strengthening said item holder with a porous backing and applying said vacuum to said part holder through said porous backing.

Claim 8

The method of claim 4 wherein said membrane has a substantially planar surface and wherein said membrane is vibrated in directions transverse to said surface.

Claim 9

The method of claim 4 including the step of radially tensioning said membrane while it is vibrated.

Claim 10

The method of claim 4 wherein said step of vibrating the membrane comprises providing a loudspeaker having a frame and a vibratory cone, affixing the membrane to said frame to enclose a volume of air between the cone and membrane, and driving said loudspeaker.

Claim 11

Apparatus for patterned placement of items on a substrate comprising: an item holder having a predetermined pattern of item locations configured and arranged to receive, seat and detachably secure an item, means for detachably securing a plurality of items to said item holder with one item being positioned at each of a group of said item locations, said means for securing comprising a vibratory membrane positioned adjacent to but spaced from said item holder and means for vibrating the membrane to project items placed on said membrane toward said item holder, means for moving said item holder with items attached thereto into an item positioning location wherein the pattern of item locations on said item holder is in registration with a predetermined pattern of item locations on a substrate, and means for releasing the securement of said items to said item holder to thereby position each of said items at an individual one of the item locations of said substrate.

Claim 12

Apparatus for patterned placement of items on a substrate comprising: an item holder having a predetermined pattern of item locations configured and arranged to receive, seat and detachably secure an item, means for detachably securing a plurality of items to said item holder with one item being positioned at each of a group of said item locations, said means for securing comprising a vibratory membrane positioned adjacent to but spaced from said item holder and means for vibrating the membrane to project items placed on said membrane toward said item holder, means for moving said item holder with items attached thereto into an item positioning location wherein the pattern of item locations on said item holder is in registration with a predetermined pattern of item locations on a substrate, and means for releasing the securement of said items to said item holder to thereby position each of said items at an individual one of the item locations of said substrate.

Claim 13

The apparatus of claim 10 wherein said item holder comprises a sheet having a plurality of apertures positioned in a predetermined pattern that matches the pattern of item locations on said substrate, each of said apertures comprising one of said item holder locations, and means for drawing a vacuum through said apertures to hold items to said sheet at said apertures.

Claim 14

The apparatus of claim 11 wherein said sheet comprises a sheet of foil and a stiffener therefor, said stiffener comprising a relatively stiff and self-supporting porous member secured to said sheet.

Claim 15

The apparatus of claim 10 wherein said item holder comprises a vacuum housing defining a vacuum chamber, a thin sheet forming one side of said chamber and having a plurality of apertures extending therethrough in a predetermined pattern, and means for drawing a vacuum in said chamber.

Claim 16

The apparatus of claim 13 wherein said sheet comprises a thin sheet of foil and a self-supporting porous backing member in said chamber secured to one side of said foil, whereby vacuum may be drawn through said porous backing member to holes in said foil.

Claim 17

The apparatus of claim 11 including means for moving said item holder from said vibratory means and for moving said item holder to a substrate having a predetermined pattern of item locations, means for terminating said vacuum to thereby release items from said item holder when said item holder locations and the items detachably secured thereto are in registration with item locations of said substrate.

Claim 18

The apparatus of claim 10 wherein said items comprise generally spherical solder preforms and wherein said item locations of said substrate comprise a printed pattern of solder flux.

Claim 19

Apparatus for placing spherical solder preforms onto a substrate pre-printed with a predetermined flux pattern, said pattern comprising: a thin foil having a plurality of circular holes formed therethrough, said holes forming a pattern that is the same as said flux pattern of said substrate, each of said holes having a diameter less than the diameter of each of said solder preforms, a housing defining a vacuum chamber having said foil sheet forming one side thereof, a vacuum port for decreasing pressure within said vacuum chamber, a stiff porous backing secured to said foil within said chamber, said porous backing having a planar surface that controls planarity of said foil, a frame positioned adjacent said foil and lying in a plane parallel to and spaced from sail foil, a vibratory membrane bridging said frame to form a part projection space between said foil member and said membrane, an air permeable skirt carried by said frame and enclosing said projection space, and means for vibrating said membrane to thereby randomly project discrete spherical preforms within said projection space from said membrane to said metal foil, thereby causing some of said preforms to be attached to said metal foil at said metal foil apertures when vacuum is applied to said vacuum chamber.

Claim 20

Apparatus for placing spherical solder preforms onto a substrate pre-printed with a predetermined flux pattern, said pattern comprising: a thin foil having a plurality of circular holes formed therethrough, said holes forming a pattern that is the same as said flux pattern of said substrate, each of said holes having a diameter less than the diameter of each of said solder preforms, a housing defining a vacuum chamber having said foil sheet forming one side thereof, a vacuum port for decreasing pressure within said vacuum chamber, a stiff porous backing secured to said foil within said chamber, said porous backing having a planar surface that controls planarity of said foil, a frame positioned adjacent said foil and lying in a plane parallel to and spaced from sail foil, a vibratory membrane bridging said frame to form a part projection space between said foil member and said membrane, an air permeable skirt carried by said frame and enclosing said projection space, and means for vibrating said membrane to thereby randomly project discrete spherical preforms within said projection space from said membrane to said metal foil, thereby causing some of said preforms to be attached to said metal foil at said metal foil apertures when vacuum is applied to said vacuum chamber.