Cushion for packing disks such as semiconductor wafers

Abstract

A cushion device ( 40 ) for packing disks ( 22 ) such as semiconductor wafers has a base ( 42 ) that is selectively secured within a container ( 20 ). The cushion ( 40 ) includes a plurality of cushion members ( 60 ) each having two ends supported by the base ( 42 ). In a disclosed example, the cushion members ( 60 ) have a stepped configuration between the two ends. Angles between adjacent generally linear portions of the stepped configuration change as the cushion members flex responsive to engaging a semiconductor wafer within the container. A disclosed example includes a contacting portion ( 90 ) near a vertex ( 92 ) between two adjacent linear portions of a cushion member ( 60 ). One example has contacting portions ( 90 ) of aligned cushion members spaced at an angle between about 65° and about 180°.

1 . A device for packing at least one disk, comprising; 
 a base; and    a plurality of cushion members having 
 a first end supported by the base and  
 a second end supported by the base,  
   each cushion member having a plurality of generally linear segments between the first and second ends, adjacent ones of the generally linear segments are transverse to each other, each cushion member having at least one contacting portion for contacting a disk near at least one vertex between two of the generally linear segments.    
   
   
       2 . The device of  claim 1 , comprising a first plurality of the cushion members having first ends supported near one lateral edge of the base and second ends supported near a central portion of the base and a second plurality of the cushion members having first ends supported near an opposite lateral edge of the base and second ends supported near the central portion of the base.  
   
   
       3 . The device of  claim 2 , wherein the second ends of the first plurality of cushion members is spaced from the first ends of the second plurality of cushion members.  
   
   
       4 . The device of  claim 2 , wherein the base includes openings between the first and second ends of each of the plurality of cushion members.  
   
   
       5 . The device of  claim 4 , wherein the base includes spaced apart support portions near the central portion of the base, each of the spaced apart support portions supporting the second ends of a corresponding one of the plurality of cushion members.  
   
   
       6 . The device of  claim 1 , wherein each cushion member has a plurality of the contacting portions.  
   
   
       7 . The device of  claim 1 , wherein a first of the cushion members and a second of the cushion members aligned with and parallel to the first cushion member are positioned so that the contacting portions of the first and second cushion members are spaced apart such that an angle between respective reference lines from each of the first and second cushion member contacting portions to a point corresponding to a center of a disk if the disk were engaged by the first and second cushion members is in a range from about 65° to about 180°.  
   
   
       8 . The device of  claim 7 , wherein the angle is in range from about 100° to about 170°.  
   
   
       9 . The device of  claim 7 , wherein the angle is in a range from about 120° to about 160°.  
   
   
       10 . The device of  claim 7 , wherein the angle is about 150°.  
   
   
       11 . The device of  claim 1 , wherein each generally linear segment of each cushion member is generally perpendicular to an adjacent linear segment of the corresponding cushion member.  
   
   
       12 . The device of  claim 11 , wherein at least the linear segments on each side of the vertex near the contacting portion of each cushion member move relative to each other responsive to engagement between the contacting portion and a disk.  
   
   
       13 . The device of  claim 1 , comprising a container top and a container bottom adapted to contain at least one disk and wherein the base is received at least partially against a portion of the top.  
   
   
       14 . The device of  claim 13 , wherein the top includes a plurality of locking members that secure the base in a desired position relative to the top.  
   
   
       15 . A device for packing at least one disk, comprising: 
 a base; and    a plurality of cushion members depending from the base,    each cushion member having at least one contacting portion for contacting a surface on a disk, the contacting portion on a first cushion member and the contacting portion on a second cushion member aligned with and parallel to the first cushion member are spaced apart such that an angle between respective reference lines from each of the first and second cushion member contacting portions to a point corresponding to a center of a disk if the disk were engaged by the first and second cushion members is in a range from about 65° to about 180°.    
   
   
       16 . The device of  claim 15 , wherein the angle is in range from about 100° to about 170°.  
   
   
       17 . The device of  claim 15 , wherein the angle is in a range from about 120° to about 160°.  
   
   
       18 . The device of  claim 15 , wherein the angle is about 150°.  
   
   
       19 . The device of  claim 15 , wherein each cushion member includes 
 a first end supported by the base and    a second end supported by the base,    each cushion member having a plurality of generally linear segments between the first and second ends with the at least one contacting portion for contacting a disk near at least one vertex between two of the generally linear segments.    
   
   
       20 . The device of  claim 19 , wherein each generally linear segment of each cushion member is generally perpendicular to an adjacent linear segment of the corresponding cushion member.