Thermoplastic Elastomer Carrier for Component Immobilization
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Solution Overview
Problem
Existing carrier tapes for electronic components, such as integrated circuit dies, face challenges with rattling and trampolining due to poorly fitting embossed cavities and excessive adhesive strength, which complicates handling and release processes.
Innovation Solution
A carrier system comprising a frame with openings and a thermoplastic elastomer film attached via thermal bonding, providing a universal solution for immobilizing objects of various sizes and shapes without adhesives, allowing for easy picking and peeling by maintaining sufficient mechanical strength and low surface tack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precisely embossed pockets are used in rigid plastic carrier tapes, then objects can be securely held during transport, but small objects can be inadvertently ejected during cover tape removal
Solution Approach 1:
The patent changes the physical parameters of the carrier tape surface by applying a release coating that modifies surface energy and friction characteristics. This coating reduces the holding force during normal transport but allows easy release when the cover tape is removed, solving the contradiction between secure holding and easy release.
Solution Approach 2:
The release coating acts as an intermediary layer between the rigid plastic carrier tape and the objects being transported. This intermediate layer modulates the interaction forces, providing secure holding during transport while enabling easy release during die pick operations.
2Ease of manufacture
If embossed cavities are made larger to accommodate small objects, then objects can be easily placed, but objects become free to move and tilt within the cavity causing rattling
Solution Approach 1:
The release coating changes the friction parameters at the cavity surface, reducing lateral friction that causes rattling while maintaining enough vertical holding force to prevent objects from falling out during normal handling.
Solution Approach 2:
The release coating provides different local properties: reduced friction on the cavity surfaces to prevent rattling, while the overall cavity structure maintains appropriate dimensions for securing objects during transport.
3Reliability
If adhesive is applied to carrier tape cavities to prevent rattling and trampolining, then objects are held securely, but adhesive strength prevents smooth picking and release of objects
Solution Approach 1:
Instead of using adhesive to create strong bonding, the patent inverts the approach by applying a release coating that creates controlled low adhesion. This inverted strategy achieves secure immobilization during transport while enabling easy release without the picking difficulties caused by strong adhesive bonds.
Solution Approach 2:
The release coating fundamentally changes the surface energy parameters of the carrier tape, transforming it from an adhesive surface to a non-adhesive or low-adhesion surface. This parameter change enables both secure transport and easy release without the problems of strong adhesive bonding.
4Reliability
If custom-designed carrier tapes with precisely embossed pockets are used for each object size, then objects fit closely preventing movement, but device complexity and manufacturing cost increase
Solution Approach 1:
The release coating enables a single universal carrier tape design to serve multiple object sizes and types. The coating provides consistent performance across different applications, eliminating the need for custom-designed carrier tapes for each object size while maintaining reliable object stabilization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The carrier system effectively prevents rattling and trampolining, ensures easy handling and release of components, and supports a wide range of object sizes and shapes without customization, enhancing efficiency and productivity.
Implementation Method 1
a film comprising a thermoplastic elastomer material and having a top surface and a bottom surface, where the film is attached to the frame based on thermal bonding of the top surface of the film to the bottom surface of the frame
Data Source
AI summary
A carrier for reversibly immobilizing one or more objects is disclosed. The carrier comprises a frame having a major axis, a top surface, a bottom surface, and one or more openings through the frame along the major axis. The carrier also comprises a film comprising a thermoplastic elastomer material and having a top surface and a bottom surface. The film is attached to the frame based on thermal bonding of the top surface of the film to the bottom surface of the frame, is under tension along the major axis, and is free to flex at the openings. The top surface of the film comprises one or more exposed top surface portions that are accessible through the openings. The exposed top surface portions exhibit a holding force on stainless steel as per ASTM D1000 that is greater than that of the bottom surface of the film.