Universal packaging tray for disk drive assembly

Abstract

A universal component carrier tray for use in assembly line production of disk drives includes a framework structure that defines a number of openings of variable size and geometry. Tray portions having form fitting structure for receiving the unique and varying configured componentry of disk drives are removably seatable into the openings. The framework and tray portions are preferably injection molded for facilitating extended life and better constaint of the componentry. The trays have stacking structure allowing a plurality of the trays to be stacked whereby each tray stacked above a tray serves as a retainer or closure for the tray below that may prevent the components from being dislodged or misoriented from the holding structure during handling of the stack and protect the components from particulate contamination.

1 . A universal component carrier system for use in assembly line production of disk drives in combination with a plurality of sets of disk drive componentry, each set of componentry comprising parts for the assembly of a portion of or all or a disk drive, the component carrier system comprising: 
 a plurality of like configured component carrier trays in a vertically stacked arrangement, each tray comprising:    a horizontally extending framework structure that defines a plurality of openings, said framework structure having an upper face;    a plurality of removable inserts, each of said inserts having a base surface with upwardly extending structure for form fitting individual ones of said parts; and    wherein each tray of said stacked arrangement that is seated on another tray with componentry therein provides a cover said disk drive components contained in said another tray.    
   
   
       2 . The universal component carrier system of  claim 1 , wherein the framework structure is configured as a lattice structure and wherein at least two of said openings of each carrier tray is of varying geometry.  
   
   
       3 . The universal component carrier system of  claim 2  wherein each of said inserts are held in position by friction between said perimeter of said insert and said lattice structure.  
   
   
       4 . The universal component carrier system of  claim 2  further comprising: 
 a clip integral to said insert, said clip having a free end extending beyond said perimeter of said insert;    a retention finger cantilevered from said upper face of said lattice structure and extending over one of said openings;    wherein said insert is mounted between said retention finger and said support structure; and    said free end of said clip engages said lattice structure.    
   
   
       5 . The universal component carrier system of  claim 2  wherein each tray serves as a lid or closure for a tray below for preventing said disk drive components from being dislodged from said inserts.  
   
   
       6 . A method of arranging componentry for assembly of disk drives comprising the steps of: 
 (a) providing a plurality of stackable like-configured component trays, each tray comprising a framework base having a plurality of openings for receiving insert tray portions,    (b) placing in said plurality of openings a plurality of tray portions, each tray portion having form fitting structure for receiving disk drive componentry,    (c) placing sets of disk drive componentry in each of said tray portions,    (d) stacking the plurality of stackable like-configured component trays in a stack and moving same to an assembly area whereby the componentry may be removed from each of the component trays in the stack.    
   
   
       7 . The method of  claim 6  further comprising the step of injection molding the plurality of like configured component trays.  
   
   
       8 . The method of  claim 7  further comprising the step of injection molding the plurality of tray portions.  
   
   
       9 . A component tray system for assembly of hard disk drives comprising a component tray having: 
 a lattice structure having a frame portion and at least one cross-member integral to said frame portion that defines a plurality of openings, said lattice structure having a lower surface that defines a registration plane;    a support structure that depends from said lattice structure, said support structure extending laterally into said openings and having an upper surface that is substantially flush with said registration plane;    a removable insert having a mounting surface, a leading edge and a perimeter, said perimeter dimensioned to fit within one of said openings, said insert contacting said support structure when placed in said opening;    a plurality of protrusions extending from said mounting surface, said protrusions arranged and shaped to secure a component.    
   
   
       10 . The component tray system of  claim 9  wherein at least one of said cross-members includes a rib portion extending below said lower surface of said cross-member.  
   
   
       11 . The component tray system of  claim 9  wherein said perimeter of said insert slidably engages said lattice structure, thereby frictionally retaining said insert within said lattice structure.  
   
   
       12 . The component tray system of  claim 9  further comprising a multiplicity of nubs that protrude laterally from said lattice structure into said openings, such that said perimeter of said insert slidably engages said nubs, thereby frictionally retaining said insert within said lattice structure.  
   
   
       13 . The component tray system of  claim 9  wherein said component is oriented to have an upper extremity, said protrusions being dimensioned to position said upper extremity at a predetermined distance from said registration plane.  
   
   
       14 . The component tray system of  claim 13  further comprising: 
 a retention finger depending from said lattice structure and extending partially over at least one of said openings;    a clip having a proximate end portion depending from said insert and a distal end portion opposite said proximate end portion; and    wherein said leading edge of said insert fits beneath said retention finger and said distal end portion of said clip engages said lattice structure.    
   
   
       15 . The component tray system of  claim 14  wherein said distal end portion of said clip further comprises a barb, said barb engaging said lower surface of said lattice structure.  
   
   
       16 . The component tray system of  claim 15  further comprising a plurality of spacers extending upward from said lattice structure.  
   
   
       17 . The component tray system of  claim 16  further comprising: 
 an upper component tray;    a lower component tray;    said upper component tray being supported by said spacers of said lower component tray; and    said upper component tray contacting said component of said lower component tray to retain said component of said lower component tray on said protrusions of said insert of said lower component tray.    
   
   
       18 . The component tray system of  claim 16  further comprising: 
 an upper component tray;    a lower component tray;    said upper component tray being supported by said spacers of said lower component tray; and    said upper component tray contacting at least one of said protrusions to retain said component of said lower component tray on said protrusions of said insert of said lower component tray.    
   
   
       19 . The component tray system of  claim 16  further comprising: 
 a lower component tray;    an upper component tray having a skirt projecting downward from said lattice structure of said upper component tray; and    wherein said upper component tray is placed over said lower component tray to enclose said component of said lower component tray.    
   
   
       20 . The component tray system of  claim 16  further comprising: 
 a lower component tray having a ridge extending upward from said lattice structure of said lower component tray;    an upper component tray having a skirt projecting downward from said lattice structure of said upper component tray; and    wherein said skirt of said upper component tray and said ridge of said lower component tray cooperate to enclose said component of said lower component tray.    
   
   
       21 . The component tray system of  claim 16  wherein said lattice structure and said support structure is injection molded.  
   
   
       22 . The component tray system of  claim 16  wherein said plurality of inserts are injection molded.  
   
   
       23 . A component tray system for assembly of hard disk drives including a component tray and a set of disk drive components for assembly of a single disk drive, said tray comprising: 
 a lattice structure defining a plurality of tray portion receiving regions;    a plurality of removable tray portions sized to seat within said tray portion receiving regions;    form fitting structure on said removable tray portions sized for constraining individual components of said set of disk drive components for assembly of said single disk drive.    
   
   
       24 . The component tray system of  claim 23  further comprising a plurality of like configured trays arranged in a stack, each tray having stacking structure to laterally constrain each tray with respect to an adjacent stacked tray.