Carrier tape for electronic components

Abstract

A flexible carrier tape for transporting a plurality of components includes a flexible substrate extending along one longitudinal direction of the carrier tape. A plurality of first recesses and second recesses are formed in the flexible substrate and arranged along the longitudinal direction of the carrier tape. At least each of the first recesses is configured to receive one of the components therein. Each of the first and second recesses includes a recess opening for receiving the component therethrough and into the recess, and a bottom wall including a main inner surface facing the recess and a opposing main outer surface below the substrate. The main inner surface and the main outer surface are spaced apart from the recess opening by a recess height and a recess thickness, respectively. The recess height and recess thickness of the first recesses are smaller than the recess height and recess thickness of the second recesses, respectively.

Description

Technical Field

[0001] This disclosure generally concerns carrier tapes, and more specifically, carrier tapes used in electronic components. Prior Technology

[0002] As electronic devices become smaller, there is a growing desire to design and manufacture electronic components (such as integrated circuit (IC) chips) to be lighter and smaller. Methods for storing and / or transporting such components have evolved over the years. One such method is the use of carrier tapes. Carrier tapes are used to store and transport electronic components (such as resistors, capacitors, or integrated circuits) from component manufacturers to different manufacturers assembling the components carried within the carrier tape. These electronic components are then mounted onto printed circuit boards (PCBs) or other substrates during the assembly of the electronic device or later, into sub-assemblies that will be used to construct that electronic device. Summary of the Invention

[0003] In some embodiments disclosed herein, a flexible carrier tape for transporting a plurality of components includes a flexible substrate extending along one longitudinal direction of the carrier tape. A plurality of spaced-apart first and second recesses are formed in the flexible substrate and arranged along the longitudinal direction of the carrier tape. At least each of the first recesses is configured to receive one of the components therein. Each of the first and second recesses includes a recess opening for receiving the component therethrough and into the recess. A bottom wall includes a main inner surface facing the recess and a opposing main outer surface below the substrate. The main inner surface and the main outer surface are spaced apart from the recess opening by a recess height and a recess thickness, respectively. The recess height and recess thickness of the first recesses are smaller than the recess height and recess thickness of the second recesses, respectively.

[0004] In some other embodiments disclosed herein, a flexible carrier belt for transporting a plurality of components includes a plurality of spaced-apart recesses and protrusions, the recesses and protrusions being alternately arranged along one longitudinal direction of the carrier belt. Each of the recesses is configured to receive one of the components therein and includes a recess opening for receiving the component through it into the recess, and a bottom wall. The protrusions extend beyond the bottom walls of the recesses and are shaped such that when a carrier tape assembly is formed by placing one of the components in each of the recesses and attaching a cover tape to the carrier tape to seal the components in the recesses; and when the carrier tape assembly is wound around a carrier reel to form a plurality of concentric loops of the carrier tape assembly, for each pair of adjacent inner and outer loops: the bottom walls of the recesses in the inner loop do not contact the cover tape body in the outer loop; and the protrusions in the inner loop do not push any portion of the cover tape in the outer loop into any of the recesses in the outer loop.

[0005] Other aspects of this disclosure relate to a carrier belt assembly for transporting a plurality of components. The carrier belt assembly includes a carrier belt according to one or more embodiments of this disclosure. Each of the first recesses of the carrier belt has one of the components disposed therein. A cover belt is engaged to a top surface of the carrier belt to seal the first recesses and the second recesses. Simple Explanation of the Diagram

[0006] Various embodiments of the present disclosure will be discussed in more detail with reference to the accompanying drawings, in which: [Fig. 1] schematically shows a flexible carrier tape having a plurality of spaced-apart recesses according to some embodiments of the present disclosure; [Fig. 2] and [Fig. 3] schematically show cross-sectional views of flexible carrier tapes according to some embodiments of the present disclosure; [Fig. 4] schematically shows a top view of a flexible carrier tape having spaced-apart first and second recesses; [Fig. 5] schematically shows a carrier tape assembly including a flexible carrier tape according to some embodiments of the present disclosure; [Fig. 6a] schematically shows a carrier tape wound around a carrier reel according to some embodiments of the present disclosure; [Fig. 6b] schematically shows a cross-sectional view of a carrier tape having anti-nesting features wound around a carrier reel according to some embodiments; and [Figs. 7a] to [Fig. 7g] schematically show different designs of recesses formed on the flexible carrier tape.

[0007] Diagrams are not necessarily drawn to scale. Similar numbers used in diagrams refer to similar components. However, it will be understood that using component symbols to refer to components in a given diagram is not intended to limit components to having the same component symbols in another diagram. Implementation

[0008] The following description is made with reference to the accompanying drawings, which form part of this document and illustrate various embodiments in a illustrative manner. It should be understood that other embodiments are contemplated and can be implemented without departing from the scope or spirit of this description. Therefore, the following detailed description is not intended to be limiting.

[0009] The flexible carrier tape disclosed herein is generally used in conjunction with components, particularly electronic components including memory chips, integrated circuit chips, resistors, connectors, processors, and the like. The carrier tape includes a plurality of recesses formed at regular intervals within the carrier tape. The geometry of the recesses is compatible with the components to be carried, and the components are positioned within the defined recesses. The recesses of the carrier tape carrying the electronic components generally seal the upper opening (e.g., using a cover tape, such as a pressure-sensitive adhesive cover tape), and the carrier tape is wound around a core or reel for storage or delivery. Due to winding tension, the bottom wall of the top recess can press against the component in the bottom recess, causing the component to adhere to the cover tape during unloading in the PCB assembly process. The embodiments described herein address these and other challenges.

[0010] Referring to Figures 1 to 5, a flexible carrier tape (200) may include a flexible substrate (20) extending along the longitudinal axis (x-axis) of the carrier tape (200). The flexible carrier tape (200) may be configured to store and / or transport a plurality of components (10). A plurality of spaced-apart recesses (30, 40) arranged along the longitudinal direction of the carrier tape (200) may be formed in the flexible substrate (20). The flexible carrier tape (200) may have a monolithic construction. The flexible carrier tape according to this disclosure may have dimensions suitable for use with a particular desired electronic component, and the recesses (30, 40) may be spaced apart from each other to be suitable for a particular application. Each of the recesses (30) may be configured to receive one of the components (10) therein. For example, each of the recesses (30) may include a recess opening (31) for receiving a component (10) therethrough and into the recess (30). In some cases, the cavity (30) may be less than 1 mm in size.

[0011] The carrier tape (200) disclosed herein can be made of any suitable material, including, for example, thermoplastic polymers, cardboard, and / or metal foil. Furthermore, the material that can be used for the carrier tape (200) can be dimensionally stable, durable, and easily molded into a desired configuration. Preferably, the material includes a thermoplastic polymer with sufficient thickness and flexibility to allow it to be wound around the hub of a storage reel. Suitable thermoplastic polymers include, but are not limited to, polyesters (e.g., glycol-modified polyethylene terephthalate, or polybutylene terephthalate), polycarbonate, polypropylene, polystyrene, polyvinyl chloride, acrylonitrile-butadiene-styrene, amorphous polyethylene terephthalate, polyamide, polyolefins (e.g., polyethylene, polybutene, or polyisobutylene), modified poly(phenylene ether), polyurethane, polydimethylsiloxane, acrylonitrile-butadiene-styrene resin, and polyolefin copolymers. In some embodiments, the material may have a melting temperature ranging from about 400℉ (204°C) to about 630℉ (332°C). The carrier tape may be optically clear, colored, or modified to be electrically dissipative. In the latter case, the carrier tape may include an electrically conductive material (e.g., carbon black or vanadium pentoxide) dispersed within the resin material or coated on the surface(s) of the formed carrier tape. The electrically conductive material helps dissipate discharges that may occur when the cover film is removed or when the carrier tape assembly is unwound from the storage reel, thus helping to prevent damage to electronic components contained in the recesses of the carrier tape. Furthermore, dyes, colorants, pigments, UV stabilizers, or other additives may be added to the resin material prior to the formation of the carrier tape.

[0012] In some embodiments, as best shown in Figures 2 and 3, a plurality of spaced-apart recesses may include a plurality of spaced-apart first recesses (30) and a plurality of spaced-apart second recesses (40). In some embodiments, the plurality of spaced-apart first recesses (30) and second recesses (40) may be formed in an array in a flexible substrate (20). In some embodiments, the first recesses (30) and second recesses (40) may be alternately arranged along the longitudinal direction (x-axis) of the carrier tape (200). In other embodiments, each of the first recesses (30) may be disposed between two of the second recesses (40) along the longitudinal direction (x-axis) of the carrier tape (200). In some embodiments, at least one of the first recesses (30) may be configured to receive one of the components (10) therein. In some embodiments, the second recesses (40) may be unconfigured as dummy recesses receiving any of the components therein.

[0013] In some embodiments, each of the first recesses (30) may include a recess opening (31) for receiving the assembly (10) therethrough and entering the recess (30), and a bottom wall (32). Each of the second recesses (40) may include a recess opening (41) and a bottom wall (42). The bottom wall (32) of each of the first recesses (30) may include a main inner surface (33) facing the first recess (30) and a opposing main outer surface (34) below the substrate (20). The bottom wall (42) of each of the second recesses (40) may include a main inner surface (43) facing the first recess (40) and a opposing main outer surface (44) below the substrate (20).

[0014] In some embodiments, the second recess (40) may have opposing sidewalls (45, 46), as shown in FIG4. The opposing sidewalls (45, 46) of the second recess (40) extend generally along a transverse direction (y-axis) orthogonal to the longitudinal direction (x-axis) of the carrier belt (200). In some cases, in a top plan view (xy plane), the sidewalls (45, 46) may be substantially straight and orthogonal to the longitudinal direction.

[0015] As shown in Figure 3, the inner surface (33) of the bottom wall (32) of each of the first recesses (30) may be separated from the recess opening (31) by a recess height (h1) and a recess thickness (t1). The inner surface (43) of the bottom wall (42) of each of the second recesses (40) may be separated from the recess opening (41) by a recess height (h2) and a recess thickness (t1). In some configurations, the recess height (h1) and recess thickness (t1) of each of the first recesses (30) may be smaller than the recess height (h2) and recess thickness (t2) of each of the second recesses (40).

[0016] In some embodiments, the flexible carrier tape (200) may include a plurality of spaced-apart recesses (30) and protrusions (80) alternately arranged along the longitudinal direction (x-axis) of the carrier tape (200), as best seen in FIG2. In some embodiments, the plurality of spaced-apart recesses (30) may be formed in an array in a flexible substrate (20). Each of the recesses (30) may include a bottom wall (32), and a protrusion (80) formed by a second recess (40) may extend beyond the bottom wall (32) of the recess (30). Each of the protrusions (80) may define a dummy recess (40) therein. A dummy recess (40) may include a recess opening (41) at a top surface (21) of one of the flexible carrier tapes (200) and may be configured therein as any of the receiving components.

[0017] A plurality of optional through-holes (60) may be provided in the flexible substrate (20) of the carrier tape (200) to facilitate mechanical operation of the carrier tape. The through-holes (60) may be spaced apart along the longitudinal direction of the flexible carrier tape. In some embodiments, other structures (e.g., notches or printed markings) may be used in place of the through-holes (60), or other structures may be used in addition to the through-holes. The through-holes (60) may be provided, for example, along one or both longitudinal edges of the carrier tape (200). The through-holes (60) may engage with teeth on a tooth actuator (not shown), which may be present in a drive assembly of a precision placement device for removing components from recesses in the carrier tape. The through-holes (60) may be used to advance the carrier tape (200) to a predetermined position such that the component (10) may be placed in or removed from a recess (30) of the carrier tape (200).

[0018] A carrier tape assembly (300) for transporting a plurality of components (10) according to some embodiments is illustrated in FIG. 5. In some cases, the components (10) may have a thickness of about 0.05 mm to about 0.15 mm. In some cases, the components (10) may be electronic components, including memory chips, integrated circuit chips, resistors, connectors, processors, and the like. The assembly (300) may include a carrier tape (200) according to one or more embodiments of the present disclosure. Each of the first recesses (30) of the carrier tape (200) may have one of the components (10) disposed therein. In some embodiments, no component (10) is disposed therein in the second recesses (40). A cover tape (70) may be engaged to the top surface (21) of the carrier tape (200) to seal the first recesses (30) and the second recesses (40). The cover tape (70) may be a pressure-sensitive adhesive (PSA) tape, such as 3M™ Pressure Sensitive Cover Tape 2698, 3M™ High Shear Pressure Sensitive Cover Tape 2668, or similar.

[0019] The carrier tape (200) can be used to transport electronic components to be assembled onto a printed circuit board using, for example, surface mount technology. For example, the electronic components are held in recesses (30) within the carrier tape (200), and a continuous length of the carrier tape (200) containing the electronic components is wound around a carrier reel as a supply roll. As shown in Figures 6a and 6b, in some configurations, the carrier tape can be wound around a carrier reel (50) to form a plurality of concentric loops (51) comprising several pairs of adjacent inner loops (51a) and outer loops (51b). For each of the concentric loops (51), the recess openings (31, 41) face away from the carrier reel (50), and the bottom walls (32, 42) face the carrier reel (50).

[0020] In some embodiments, the protrusion (80) extending beyond the bottom wall (32) of the recess (30) is shaped such that when a carrier tape assembly (300) is formed by placing one of the components (10) in each of the recesses (30) and attaching a cover tape (70) to the carrier tape (200) to seal the components in the recesses, and when the carrier tape assembly (300) is wound around a carrier spool (50) to form a plurality of concentric loops (51) of the carrier tape assembly (300), for each pair of adjacent inner loops (51a) and outer loops (51b), the bottom wall (32) of the recess (30) in the inner loop (51a) does not come into physical contact with the cover tape (70) in the outer loop (51b). Furthermore, the protrusion (80) in the inner loop (51a) does not push any part of the covering strip (70) in the outer loop (51b) into any of the recesses (30) in the outer loop (51b).

[0021] In some other embodiments, such as best seen in FIG6b, when the carrier tape (200) is wound around the carrier spool (50) to form a plurality of concentric loops (51) of the carrier tape, a plurality of first recesses (30) and second recesses (40) are arranged along the longitudinal direction (x-axis) of the carrier tape, and the recess openings (31, 41) and bottom walls (32, 42) are of a fixed size and shape such that for each pair of adjacent inner loops (51a) and outer loops (51b), the main outer surface (34) of the bottom wall (32) of the first recess (30) in the outer loop (51b) does not physically contact the substrate (20) of the carrier tape (51a) in the inner loop (51a). Furthermore, the main outer surface (44) of the bottom wall (42) of the second recess (40) in the outer loop (51b) does not penetrate the recess opening (31, 41) of the first recess (30) or the second recess (40) in the inner loop (51a). According to the illustrated embodiment, when the carrier tape is wound around the carrier reel, nesting of recesses between adjacent inner and outer loops in the carrier tape can be largely avoided.

[0022] The second recess (40) with anti-nesting features can have different designs. Figures 7a to 7g illustrate some examples of designs of second recesses (40a to 40g) with anti-nesting features on the carrier tape (200a to 200g).

[0023] According to the embodiments illustrated in Figures 7a and 7b, the second recess (40a, 40b) has opposing sidewalls (45a, 46a; 45b, 46b) that extend substantially in a transverse direction (y-axis) orthogonal to the longitudinal direction (x-axis) of the carrier belt (200a, 200b). In a top plan view (xy plane), the sidewalls (45a, 46a; 45b, 46b) may be substantially parallel and straight, and not orthogonal to the longitudinal direction (x-axis).

[0024] According to the embodiment illustrated in FIG7c, the second recess (40c) has opposing sidewalls (45c, 46c) that extend generally in a transverse direction (y-axis) orthogonal to the longitudinal direction (x-axis) of the carrier belt (200c). In the top plan view (xy plane), at least a portion of the sidewalls (45c, 46c) may be curved and convex toward each other.

[0025] According to the embodiment illustrated in Figure 7d, the second recess (40d) has opposing sidewalls (45d, 46d) that extend substantially in a transverse direction (y-axis) orthogonal to the longitudinal direction (x-axis) of the carrier belt (200d). In a top plan view (xy plane), the sidewalls may have intermediate portions (45d', 46d') that are substantially straight and orthogonal to the longitudinal direction (x-axis). The intermediate portions (45d', 46d') of the sidewalls (45d, 46d) may be spaced apart by a distance d1. The sidewalls may further have end portions (45d”, 46d”) at each opposing transverse end of the sidewalls (45d, 46d), which are substantially straight and orthogonal to the longitudinal direction (x-axis) and spaced apart by a distance d2, where d2 > d1.

[0026] According to the embodiments illustrated in Figures 7e and 7f, the second recess (40e, 40f) has opposing sidewalls (45e, 46e; 45f, 46f) that extend substantially in a transverse direction (y-axis) orthogonal to the longitudinal direction (x-axis) of the carrier belt (200e, 200f). In a top plan view (xy plane), the sidewalls (45e, 46e; 45f, 46f) may be curved and substantially parallel.

[0027] According to the embodiment illustrated in Figure 7g, the second recess (40g) has opposing sidewalls (45g, 46g) that extend generally in a transverse direction (y-axis) orthogonal to the longitudinal direction (x-axis) of the carrier belt (200g). In a top plan view (xy plane), the sidewalls (45g, 46g) may have a meandering shape.

[0028] Various modifications and alterations will be obvious to those skilled in the art, and it should be understood that the scope of this disclosure is not limited to the illustrative embodiments presented herein.

[0029] 10: Components

[0030] 20: Flexible substrate; substrate

[0031] 21: Top surface

[0032] 30: Depression; First Depression

[0033] 31: Opening of the concave cavity

[0034] 32: Bottom wall

[0035] 33: Main inner surface

[0036] 34: Main outer surface

[0037] 40: Depression; Second Depression

[0038] 40a: Second depression

[0039] 40b: Second depression

[0040] 40c: Second depression

[0041] 40d: Second depression

[0042] 40e: Second depression

[0043] 40f: Second depression

[0044] 40g: Second depression

[0045] 41: Opening of the concave cavity

[0046] 42: Bottom wall

[0047] 43: Main inner surface

[0048] 44: Main outer surface

[0049] 45: Sidewall

[0050] 45a: Sidewall

[0051] 45b: Sidewall

[0052] 45c: Sidewall

[0053] 45d: Sidewall

[0054] 45e: Sidewall

[0055] 45f: Sidewall

[0056] 45g: sidewall

[0057] 45d': Middle part

[0058] 45d”: End portion

[0059] 46: Sidewall

[0060] 46a: Sidewall

[0061] 46b: Sidewall

[0062] 46c: Sidewall

[0063] 46d: Sidewall

[0064] 46e: Sidewall

[0065] 46f: Sidewall

[0066] 46g: sidewall

[0067] 46d': Middle part

[0068] 46d”: End portion

[0069] 50: Carrier Scroll

[0070] 51: Concentric Circle

[0071] 51a: Inner loop

[0072] 51b: Outer loop

[0073] 60: Chain tooth through hole

[0074] 70: Covering strip

[0075] 80:convex part

[0076] 200: Flexible carrier belt

[0077] 200a: Carrier tape

[0078] 200b: Carrier tape

[0079] 200c: Carrier tape

[0080] 200d: Carrier tape

[0081] 200e: Carrier tape

[0082] 200f: Carrier tape

[0083] 200g: Carrier tape

[0084] 300: Carrier tape assembly; Assembly

[0085] d1: Distance

[0086] d2: Distance

[0087] h1: Height of the cavity

[0088] h2: Height of the cavity

[0089] t1: Cavity thickness

[0090] t2: Cavity thickness

[0091] x: axis

[0092] y: axis

Claims

1. A flexible carrier tape for transporting a plurality of components, the flexible carrier tape comprising a flexible substrate extending along one longitudinal direction of the carrier tape, and a plurality of spaced-apart first recesses and second recesses formed in the flexible substrate and arranged along the longitudinal direction of the carrier tape, wherein at least each of the first recesses is configured to receive one of the components therein. Each of the first and second recesses includes: a recess opening for receiving the component therethrough and into the recess; and a bottom wall including a main inner surface facing the recess and a opposing main outer surface below the substrate, the main inner surface and the main outer surface being spaced apart from the recess opening by a recess height and a recess thickness, respectively; wherein the recess height and recess thickness of the first recesses are respectively smaller than the recess height and recess thickness of the second recesses, wherein the plurality of first and second recesses are arranged along the longitudinal direction of the carrier tape, and the recess opening and the bottom wall are arranged in a manner that... The carrier tape is sized and shaped such that when it is wound around a carrier spool to form a plurality of concentric loops, the recess openings of each of the concentric loops face away from the carrier spool and the bottom walls face the carrier spool. Then, for each pair of adjacent inner and outer loops: the main outer surfaces of the bottom walls of the first recesses in the outer loop do not contact the covering tape of the carrier tape in the inner loop; and the main outer surfaces of the bottom walls of the second recesses in the outer loop do not penetrate the recess openings of the first or second recesses in the inner loop.

2. The flexible carrier tape of claim 1, wherein the first and second recesses of the spaced-apart plurality of first and second recesses are alternately arranged along the longitudinal direction of the carrier tape.

3. The flexible carrier tape of claim 1, having an integral construction, wherein the second recesses are dummy recesses that are not configured to receive any of the components therein.

4. The flexible carrier tape of claim 1, wherein the second recesses have opposing sidewalls that extend in a transverse direction orthogonal to the longitudinal direction of the carrier tape, and wherein, in a top plan view, the sidewalls are parallel and straight and not orthogonal to the longitudinal direction.

5. The flexible carrier tape of claim 1, wherein the second recesses have opposing sidewalls extending in a transverse direction orthogonal to the longitudinal direction of the carrier tape, and wherein, in a top plan view, at least a portion of the sidewalls are curved and convex toward each other.

6. The flexible carrier tape of claim 1, wherein the second recesses have opposing sidewalls extending in a transverse direction orthogonal to the longitudinal direction of the carrier tape, and wherein, in a top plan view, the sidewalls have: intermediate portions that are straight and orthogonal to the longitudinal direction and spaced apart by a distance d1; and end portions that are at each opposing transverse end of the sidewalls, straight and orthogonal to the longitudinal direction and spaced apart by a distance d2, d2>d1.

7. A carrier belt assembly for transporting a plurality of components, comprising: a carrier belt as claimed in claim 1; each of the first recesses having one of the components disposed therein; and a cover belt engaged to a top surface of the carrier belt and sealing the first and second recesses, wherein none of the second recesses has any of the components disposed therein.

8. A flexible carrier belt for transporting a plurality of components, the flexible carrier belt comprising a plurality of spaced-apart recesses and protrusions alternately arranged along a longitudinal direction of the carrier belt, each of the recesses being configured to receive one of the components therein and including a recess opening for receiving the component therein and into the recess, and a bottom wall, the protrusions extending beyond the bottom walls of the recesses and being shaped such that: by placing one of the components in each of the recesses and... When a cover tape is joined to the carrier tape to seal the components in the recesses to form a carrier tape assembly; and the carrier tape assembly is wound around a carrier spool to form a plurality of concentric loops of the carrier tape assembly, for each pair of adjacent inner and outer loops: the bottom walls of the recesses in the outer loop do not contact the cover tape body in the inner loop; and the protrusions in the outer loop do not push any portion of the cover tape in the inner loop into any of the recesses in the inner loop.

9. The flexible carrier tape of claim 8, wherein each of the protrusions defines a recess therein. The dummy recess includes a recess opening at the top surface of one of the flexible carriers, the dummy recess being unconfigured to receive any of the components therein.

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