Carrier tape with integrated cover tape

Abstract

Embodiments of a carrier tape having an integrated cover tape are disclosed. The carrier tape may comprise a base having a number of spaced-apart pockets. A first cover tape piece and a second cover tape piece may each be secured to the carrier tape base. Opposing inner ends of the first and second cover tape pieces extend toward the center of the carrier tape base and over portions of the pockets, and a gap exists between these opposing inner edges. The gap overlies the pockets, but this gap is sized to retain parts within the pockets when the cover tape pieces are "at rest." A separator tool may be inserted within this gap and underneath the first and second cover tape pieces, and this separator tool may spread apart the cover tape pieces, allowing parts to be removed from or placed in the carrier tape. Other embodiments are described and claimed.

Description

FIELD OF THE INVENTION

[0001] The disclosed embodiments relate generally to media for handling parts, such as integrated circuit devices, and more particularly to a carrier tape having an integrated cover tape.

BACKGROUND OF THE INVENTION

[0002] A carrier tape capable of holding a number of parts, such as integrated circuit (IC) die, may be utilized to facilitate automation and handling of these components. A typical carrier tape comprises a flexible tape having a row (or multiple rows) of evenly spaced pockets distributed along it's length. Each pocket is configured to receive an individual part--e.g., a bare die, a packaged die or other die assembly, etc.--and a cover tape may be adhered to an upper surface of the carrier tape to cover each pocket (and perhaps retain the die on the carrier tape). A pressure sensitive adhesive or heat activated adhesive may be used to secure the cover tape onto the carrier tape. The carrier tape can be wound onto a tape reel, and a row of small indexing holes may be distributed along the length of the carrier tape adjacent an edge of the tape, these indexing holes facilitating movement of the carrier tape and/or tape reel by automated handing equipment.

[0003] To hold parts in their respective pockets on a carrier tape, an adhesive may be pre-applied in each of the pockets. When a part is placed in a pocket, the part contacts the pre-applied adhesive, which secures the part within that pocket. To then remove a part from a pocket of the carrier tape, the adhesive bond between that part and the pre-applied adhesive in the pocket must be overcome in order to release the part. Use of a pre-applied pocket adhesive can present part handling and automation challenges, as release of parts from the carrier tape may be difficult. Alternatively, as suggested above, rather than using a pre-applied adhesive in each pocket, the cover tape itself may, when adhered to the carrier tape, secure each part within it--s respective pocket. However, application and subsequent lift-off of the cover tape can also present part handling and automation problems due to the complexity of applying and removing the cover tape.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1A is a schematic diagram illustrating a top plan view of an embodiment of a carrier tape having an integrated cover tape.

[0005] FIG. 1B is a cross-sectional elevation view of the carrier tape of FIG. 1A, as taken along line B-B of FIG. 1A.

[0006] FIG. 1C is a cross-sectional elevation view of the carrier tape of FIG. 1A, as taken along line C-C of FIG. 1A.

[0007] FIG. 1D is a cross-sectional elevation view of another embodiment of the carrier tape of FIGS. 1A-1C.

[0008] FIG. 1E is a cross-sectional elevation view of a further embodiment of the carrier tape of FIGS. 1A-1C.

[0009] FIGS. 2A-2C are schematic diagrams of the carrier tape shown in FIGS. 1A-1C respectively, in conjunction with an embodiment of a separator tool.

[0010] FIGS. 3A-3C are schematic diagrams, each illustrating another embodiment of a separator tool.

[0011] FIG. 4 is a block diagram illustrating an embodiment of a method of removing parts from, or placing parts on, a carrier tape having an integrated cover tape.

[0012] FIG. 5 is a schematic diagram illustrating an embodiment of a system for removing parts from, or placing parts on, a carrier tape having an integrated cover tape.

[0013] FIG. 6 is a block diagram illustrating an embodiment of a method for making a carrier tape having an integrated cover tape.

DETAILED DESCRIPTION OF THE INVENTION

[0014] Referring to FIGS. 1A through 1C, illustrated are embodiments of a carrier tape 100 having an integrated cover tape. A top plan view of the carrier tape 100 with integrated cover tape is provided in FIG. 1A. A cross-sectional elevation view, as taken along line B-B of FIG. 1A, is shown in FIG. 1B, whereas another cross-sectional elevation view, as taken along line C-C of FIG. 1A, is shown in FIG. 1C. The carrier tape with integrated cover tape provides a carrier medium for a number of parts, such as, for example, integrated circuit die 5.

[0015] With reference to FIGS. 1A-1C, in one embodiment, the carrier tape 100 comprises a base 110 having an upper side 111 and an opposing lower side 112. Disposed on the base 110 is a row of spaced-apart pockets 120. Typically, the pockets 120 are evenly spaced apart; however, in another embodiment the pockets may not be evenly spaced. Each of the pockets 120 comprises a recess extending downward below the upper side or surface 111, and this recess is accessible from the first side 111. The pockets 120 are each capable of receiving an integrated circuit die 5 (or, alternatively, a packaged die, die assembly, or other component). An aperture 122 at the bottom of each pocket 120 may allow for insertion of a pin (from lower side 112) to assist in extraction of any component placed in a pocket 120. Although a single row of pockets 120 is shown in the figures, in other embodiments, multiple rows of pockets may be distributed along the length of the carrier tape 100. The pockets 120 may be formed by any suitable process, such as, for example, an embossing process, a molding process, etc. Also, in one embodiment, disposed along the edges (or, perhaps, one of the edges) of the base 110 is a row of indexing holes 115. A drive gear having teeth adapted to engage the indexing holes 115, or other mechanism capable of engaging the indexing holes, can be used to advance the carrier tape 100 (either alone or in combination with motion of a take-up reel).

[0016] The carrier tape 100 further comprises a cover tape, including a first cover tape piece 150a and a second cover tape piece 150b. In one embodiment, each of the cover tape pieces 150a, 150b is flexibly secured to the carrier tape 100. For example, in the illustrated embodiment, the first cover tape piece 150a is secured to the carrier tape upper surface 111 along a bond line 155a. This bond line 155a extends along the lengths of the carrier tape base 110 and first cover tape piece 150a, respectively, and this bond line 155a is disposed proximate an outer edge 151a of the first cover tape piece 150a. First cover tape piece 150a extends from the outer edge 151a over a portion 126 of each pocket 120 and to an opposing inner edge 152a. Similarly, the second cover tape piece 150b is secured to the carrier tape upper surface 111 along a second bond line 155b, the bond line 155b extending along the lengths of the carrier tape base 110 and second cover tape piece 150b, respectively. The bond line 155b is disposed proximate an outer edge 151b of the second cover tape piece 150b, and the second cover tape piece 150b extends from its outer edge 151b over a portion 127 of each pocket 120 and to an opposing inner edge 152b.

[0017] A gap 160 exists between the respective inner edges 152a, 152b of the first and second cover tape pieces 150a, 150b. As will be further described below, the gap 160 is sized and located to prevent the escape of a part (e.g., a die 5) from each of the pockets 120 when the cover tape pieces 150a, 150b are in a first "at rest" position (i.e., the positions shown in FIGS. 1A-1C). In one embodiment, the gap 160 has a width that comprises up to approximately fifty percent of the width of a pocket 120. As shown in FIGS. 1A-1C, the gap 160 may be centered approximately over a centerline of the carrier tape 100 (e.g., each of the cover tape pieces 150a, 150b may extend toward the centerline of the carrier tape approximately the same distance). However, in other embodiments, the gap 160 may be off-center.

[0018] In one embodiment, the cover tape pieces 150a, 150b are comprised of a flexible material, and the first cover tape piece 150a is capable of flexing about the bond line 155a, whereas the second cover tape piece 150b is capable of flexing about the bond line 155b (e.g., the bond lines 155a, 155b function similar to a hinges for the first and second cover tape pieces 150a, 150b, respectively). The cover tape pieces 150a, 150b are shown in a first position in FIGS. 1A-1C, wherein the first and second cover tape pieces 150a, 150b rest against (or in proximity to) the upper side 111 of the carrier tape base 110. This first position may be termed the "at rest" or "unflexed" position (although it should be understood that the cover tape pieces may be pre-stressed at this first position in order to assist in retaining parts within the pockets 120). In this first position, the cover tape pieces 150a, 150b will retain parts within the pockets 120, as the gap 160 is sufficiently narrower than a dimension of a part (e.g., a die 5) within a pocket 120 to prevent escape of the part from the pocket. However, due to the flexibility of the cover tape material and/or the ability of the cover tape pieces 150a, 150b to flex about their respective bond lines 155a, 155b, the cover tape pieces are capable of flexing to a second position at which a pocket 120 can be accessed (either to insert or remove a part), as will be described below.

[0019] The cover tape pieces 150a, 150b may be secured to the carrier tape 100 using any suitable attachment method. In one embodiment, the bond lines 155a, 155b are formed using an ultrasonic welding process. In another embodiment, the bond lines 155a, 155b are formed using an adhesive (e.g., an epoxy, a pressure sensitive adhesive, a heat activated adhesive, etc.). In a further embodiment, the bond lines 155a, 155b are formed by a thermocompression bonding process. In yet another embodiment, the carrier tape 100 and cover tape pieces 150a, 150b are integrally formed as a single part using an extrusion process. It should be understood, however, that the disclosed embodiments are not limited to the aforementioned methods of forming the carrier tape 100 with integrated cover tape pieces 150a, 150b and, further, that any suitable techniques may be employed to secure the cover tape pieces to the carrier tape base or otherwise manufacture the carrier tape 100.

[0020] In the embodiments of FIGS. 1A-1C, each of the outer edges 151a, 151b of the first and second cover tape pieces 150a, 150b, respectively, extends to a position inside one of the opposing rows of indexing holes 115, and the bond lines 155a, 155b are formed inwards of the indexing holes 115. However, the disclosed embodiments are not limited to this configuration. For example, as shown in FIG. 1D, in another embodiment the outer edges 151a, 151b of the first and second cover tape pieces 150a, 150b, respectively, may extend to the opposing outer edges of the carrier tape base 110. In this embodiment, the cover tape pieces 150a, 150b may include indexing holes 159a, 159b, respectively, aligned with the indexing holes 115 on the carrier tape base. The bond lines securing the cover tape pieces 150a, 150b to the carrier tape base 110 may be formed outwards of the indexing holes 115, 159a-b, or the bond lines may be formed inwards of the indexing holes (as shown in FIGS. 1A-1C).

[0021] In another embodiment, a shown in FIG. 1E, each of the outer edges 151a, 151b of the first and second cover tape pieces 150a, 150b, respectively, may extend over and wrap around the opposing edges of the carrier tape base 110. The cover tape pieces 150a, 150b may again includes indexing holes 159a, 159b aligned with the indexing holes 115 on the carrier tape. In the embodiment of FIG. 1E, the bond lines securing the cover tape pieces 150a, 150b to the carrier tape base 110 may lie outwards of the indexing holes 115, 159a-b, and the wrap-around configuration of the cover tape pieces 150a, 150b may form the bonds between the cover tape pieces and the carrier tape base (or at least assist in coupling the cover tape pieces to the base).

[0022] The carrier tape base 110 may comprise any suitable material. Examples of materials that may be suitable for fabrication of the carrier tape base 110 include polycarbonate, polystyrene, trilaminate polycarbonate with an ABS (acrylonitrile butadiene styrene) core, a homogeneous blend of two or more plastics, and paper (or cardboard or other wood pulp-based products). The cover tape pieces 150a, 150b may also be constructed from any suitable material. In one embodiment, the cover tape pieces 150a, 150b comprise a flexible material capable of deforming to allow placement or removal of parts from the carrier tape, as described above, and also capable of returning to their original undeformed positions after part placement or removal (e.g., without undergoing plastic deformation). Examples of materials that may be suitable for construction of the cover tape pieces 150a, 150b include polyester, polycarbonate, polystyrene, trilaminate polycarbonate with an ABS core, a homogeneous blend of two or more plastics, and paper (or cardboard or other wood pulp-based products). According to one embodiment, the carrier tape base 110 and the cover tape pieces 150a, 150b comprise the same material; however, in other embodiments the carrier tape base and the cover tape pieces comprise different materials. In another embodiment, the cover tape pieces 150a, 150b comprise a material that is capable of being bonded to the material of the carrier tape base 110 by an ultrasonic welding process. In yet another embodiment, the carrier tape base 110 and cover tape pieces 150a-b comprise a material that is amenable to formation by an extrusion process. Also, the components of carrier tape 100 may have any suitable thickness. According to one embodiment, the carrier tape base 110 has a thickness of between approximately 0.28 mm and 0.38 mm, and the cover tape pieces 150a, 150b each have a thickness of between 0.048 mm and 0.08 mm. It should be understood that, in FIGS. 1A-1E (and FIGS. 2A-2C), the respective thicknesses (and perhaps other dimensions) of the carrier tape base 110 and cover tape pieces 150a, 150b have been exaggerated for ease of illustration and, further, that no unnecessary limitations should be drawn from these figures.

[0023] Turning to FIGS. 2A-2C, the manner in which a part may be placed on or removed from the carrier tape 100 is illustrated in greater detail. The carrier tape 100 of FIGS. 1A-1C is again shown in FIGS. 2A-2C, and the elements of the carrier tape have retained the same numerical designation in FIGS. 2A-2C. Further, the lines B-B and C-C are again shown in FIG. 2A, and the same relationships exist between FIGS. 2A, 2B, and 2C as exist between FIGS. 1A, 1B, and 1C.

[0024] With reference now to FIGS. 2A-2C, a separator tool 200 has been inserted underneath the first and second carrier tape pieces 150a, 150b, and between these cover tape pieces and the upper surface 111 of the carrier tape base 110. The separator tool 200 is generally centered relative to the gap 160 and/or the centerline of the carrier tape 100. Note that in FIG. 2A, for ease of illustration, that portion of the separator tool 200 underlying the carrier tape pieces 150a, 150b is shown in solid line (rather than hidden line). In one embodiment, separator tool 200 comprises any device capable of spreading apart the first and second cover tape pieces 150a, 150b to an extent sufficient to allow access to one (or more) of the pockets 120 on carrier tape 100. In another embodiment, the separator tool 200 comprises a device capable of sufficiently separating the first and second cover tape pieces 150a, 150b to allow access to a pocket without permanently deforming (e.g., causing plastic deformation) or otherwise damaging the cover tape pieces or the bonds securing these pieces to the cover tape base 110. Also, the separator tool 200 may enable access to one pocket 120 on carrier tape 100 or, in other embodiments, the separator tool 200 may be capable of providing simultaneous access to multiple pockets on the carrier tape 100 (e.g., access to two or more pockets 120 in the row of pockets of the embodiment illustrated in the figures or, in other embodiments, access to two or more pockets in multiple rows of pockets disposed on a carrier tape).

[0025] Generally, as noted above, the separator tool 200 comprises any device capable of spreading apart the first and second cover tape pieces 150a, 150b to an extent sufficient to allow access to one (or more) of the pockets 120 on carrier tape 100. In the illustrated embodiment, the separator tool 200 comprises a body 205 having an aperture 210 extending therethrough. The aperture 210, when centered approximately over a pocket 120, provides an opening through which a part may be inserted into a pocket or, alternatively, through which a part may be removed from a pocket. In another embodiment, the aperture 210 may provide access to two or more pockets on the carrier tape. In a further embodiment, the separator tool 200 may include two or more apertures, providing access to two or more pockets on a carrier tape.

[0026] The body 205 of separator tool 200 further comprises a leading portion 220 and a trailing portion 230. Leading portion 220 has a size and shape that, when the carrier tape 100 is advanced relative to the separator tool 200 (or the separator tool advanced relative to the carrier tape), tends to lift the cover tape pieces 150a, 150b upwards while also spreading apart the respective inner edges 152a, 152b of cover tape pieces. When pushed upwards and outwards by the separator tool 200, the cover tape pieces 150a, 150b will undergo at least some flexing, although plastic deformation should be avoided or minimized. Further, the extent to which the cover tape pieces 150a, 150b deform should not lead to delamination of the bond lines 155a, 155b. In the "flexed" or "separated" condition, the cover tape pieces 150a, 150b should be separated such that a gap 165 exists between the cover tape inner edges 152, 152b (best seen in FIGS. 2A and 2C), thereby allowing access to a pocket 120 through the aperture 210 of the separator tool 200. When the separator tool 200 has created a gap 165 between the cover tape pieces 150a, 150b, a part (e.g., a die 5) may be placed or removed from one (or more) of the pockets 120 on carrier tape 100.

[0027] In one embodiment, the trailing portion 230 of separator tool body 205 has a size and shape that, when the carrier tape 100 advances relative to the separator tool 220 (or the separator tool advanced relative to the carrier tape), allows the cover tape pieces 150a, 150b to return to their respective original "at rest" positions. According to one embodiment, the trialing portion 230 has a size and shape that provides for the gradual transition of the cover tape pieces 150a, 150b from the "flexed" position to the "at rest" position. According to one embodiment, the leading and trailing portions 220, 230 of the separator tool body 205 have substantially the same size and shape; however, in other embodiments these two portions of the tool body may have different configurations.

[0028] The size and shape of the separator tool 200 shown in FIGS. 2A-2C is presented by way of example, and it should be understood that the separator tool 200 may have any other suitable shape. Some other possible configurations of a separator tool 200 are provided--by way of example and without limitation--in each of FIGS. 3A through 3C. In each of FIGS. 3A-3C, a top plan view of the separator tool 200 is shown on the left-hand side, whereas a front elevation view is shown on the right-hand side. Also, reference numerals identifying the features of the separator tool shown in FIGS. 2A-2C are used in each of FIGS. 3A-3C to identify similar features. The separator tool 200 may be constructed from any suitable material. Examples of materials believed suitable for construction of the separator tool include Teflon.RTM. and Delron.RTM.. Also, in one embodiment, the separator tool 200 is formed of a material that prevents or minimizes the potential for electrostatic discharge (ESD).

[0029] Turning next to FIG. 4, illustrated is an embodiment of a method of removing parts from, or placing parts on, the carrier tape 100 of FIGS. 1A-1C and 2A-2C. With reference to block 410 in this figure, a separator tool is inserted underneath the cover tape pieces. This was previously illustrated in FIGS. 2A-2C, where a separator tool 200 was inserted between the cover tape pieces 150a, 150b and the carrier tape base 110. Generally, the separator tool is centered in the gap 160 between the cover tape pieces 150a, 150b. To initially insert the separator tool under the cover tape pieces, an operator may manually pull apart the cover tape pieces, thereby enabling insertion of the separator tool. In another embodiment, the front end of the carrier tape (e.g., the first several inches to wind off the reel holding the carrier tape) may not include the cover tape pieces (and/or provide a wider gap that transitions down to the gap 160 shown in the figures), such that the separator tool may be slid underneath the cover tape pieces at this front end of the carrier tape. Alternatively, in a further embodiment, the separator tool may be capable of collapsing down to a width less than that of gap 160 such that the tool may be inserted through this gap. The separator tool may then be further capable of expanding out to its original width after insertion into the gap 160, such that the separator tool is now underneath the cover tape pieces and can function to spread apart these two pieces to create a wider gap 165 (see FIGS. 2A-2C).

[0030] Referring to block 420 in FIG. 4, the carrier tape is advances to align a pocket with an aperture in the separator tool. This is illustrated in FIGS. 2A-2C, where a pocket 120 on the carrier tape 100 is substantially aligned with the aperture 210 of the separator tool 200. It should be understood that, rather than advancement of the carrier tape, the separator tool may also be advanced (or both the carrier tape and separator tool may move relative to each other). Also, in an alternative embodiment, two or more pockets on a carrier tape are aligned with an aperture of a separator tool, and in yet another embodiment, two or more pockets on a carrier tape are aligned with two or more apertures of a separator tool.

[0031] Referring to block 430 in FIG. 4, as the carrier tape (and/ or separator tool) advances, the separator tool spreads apart the cover tape pieces to allow access to a pocket on the cover tape. This is also illustrated in FIGS. 2A-2C, where the separator tool 200 has separated the cover tape pieces 150a, 150b to create a gap 165. Gap 165 provides an opening that is sufficient to allow access (thru the aperture 210 in separator tool 200) to a pocket 120 on carrier tape 100. Referring to block 440, a part is inserted into a pocket, or removed from a pocket, on the carrier tape. With reference again to FIGS. 2A-2C, a part such as a die 5 may be placed in one of the pockets 120 through the gap 165 and aperture 210 of separator tool 200. Alternatively, a part (e.g., a die 5) may be removed from one of the pockets 120 through the gap 165 and aperture 210. The carrier tape 100 (and/or separator tool 200) may then be advanced again and another part inserted in or removed from the carrier tape 100 (see arrow 405), and the above-described process may be repeated until all pockets 120 on the carrier tape 100 are either occupied by a part or empty.

[0032] Turning to FIG. 5, illustrated is an embodiment of a system 500 for removing parts from, or placing parts on, a carrier tape having an integrated cover tape. System 500 includes a carrier tape mechanism 510, which comprises a source tape reel 512, a take-up reel 514, and an actuator 516 coupled with the take-up reel 514 (and/or source reel 512). Wound on the source tape reel 512 is a length of carrier tape 100 having a number of pockets 120, each pocket for receiving a die 5 (or other part). According to one embodiment, the carrier tape 100 includes an integrated cover tape, as described above. For example, the carrier tape 100 may comprise a carrier tape base 110 having first and second cover tape pieces 150a, 150b secured thereto, as described above in FIGS. 1A-1C (or 1D or 1E).

[0033] The carrier tape 100 is advanced by motion of the take-up reel 514 (and/or source reel 512) initiated by actuator 516, and the carrier tape 100 (with die 5 and integrated cover tape 150a, 150b) is wound onto the take-up reel 514. Alternatively, movement of the carrier tape 100 may be initiated by a mechanism that engages a series of indexing holes (e.g., indexing holes 115 shown in FIGS. 1A-2C) on the carrier tape 100 (either alone or in combination with motion of the take-up reel 514 produced by actuator 516). In the illustrated embodiment, the length of carrier tape 100 stored on the source tape reel 512 does not contain any die, and as the carrier tape 100 is advanced and wound onto the take-up reel 514, die 5 are placed into the pockets 120 of the carrier tape. In another embodiment, the length of the carrier tape 100 disposed on source tape reel 512 includes a number of die 5 (or other parts), and these die are removed from the carrier tape as the tape is advanced.

[0034] The system 500 further includes a pick-and-place mechanism 520 having a pick-and-place head 525. In the illustrated example, pick-and-place head 525 "picks" individual die 5 from a wafer 2 that has been diced or singulated into a number of die. Wafer 2 may be held by a wafer holding device 530 (e.g., a wafer chuck, an adhesive tape disposed on a substrate, etc.). The pick-and-place head 525 then places each die 5 into one of the pockets 120 on carrier tape 100. Alternatively, the pick-and-place mechanism may be used to remove the die 5 (or other parts) from the carrier tape 100.

[0035] To facilitate placement of parts onto (or removal of parts from) the carrier tape 100, the system 500 further includes a separator tool 200. Separator tool 200 may comprise any of the embodiments of a separator tool described above (see FIGS. 2A-2C and FIGS. 3A-3C), or other tool providing similar functionality. When the carrier tape 100 is advanced relative to the separator tool 200, the separator tool will spread apart the cover tape pieces 150a, 150b, thereby allowing the pick-and-place head 525 to insert a die 5 into (or remove a die from) a pocket 120 through the aperture 210 in the separator tool, as previously described (see, e.g., FIGS. 2A-2C and FIG. 4, and the accompanying text above). The carrier tape 100 can be incrementally advanced relative to the separator tool 200, such that a die 5 may be inserted into each of the pockets 120 on the carrier tape. Also, in a further embodiment, the separator tool 200 itself may be capable of movement relative to the carrier tape 100 (e.g., to advance the separator tool relative to the carrier tape and/or to lift and lower the separator tool relative to the carrier tape). In such an embodiment, the separator tool 200 may be coupled with a motion mechanism (not shown in FIG. 5).

[0036] In another embodiment, system 500 also includes a controller 540 communicatively coupled with the pick-and-place mechanism 520 and the actuator 516 of carrier tape mechanism 510, and each of these devices may send signals to controller and receive signals from the controller (and perform actions in response to signals received from the controller). In one embodiment, the controller may also be communicatively coupled with a motion mechanism associated with separator tool 200. The controller 540 may comprise any suitable computing device.

[0037] It should be understood that the system 500 of FIG. 5 is but one example of a system that can be employed to insert or remove parts from the carrier tape 100 and, further, that the disclosed embodiments may find application with other systems that utilize a carrier tape medium. Also, it should be understood that the system 500 may include other components not shown in FIG. 5 and/or may not include all of the components shown in FIG. 5.

[0038] Referring now to FIG. 6, illustrated is an embodiment of a method for making a carrier tape having an integrated cover tape. Referring to block 610, a carrier tape base is provided. For example, the carrier tape base may comprise the base 110 shown and described in FIGS. 1A-1C. Referring to block 620, a first cover tape piece and a second cover tape piece are secured to the carrier tape base. The first and second cover tape pieces may, for example, comprise the cover tape pieces 150a, 150b shown and described above in FIGS. 1A-1C (or 1D or 1E). The cover tape pieces may be secured to the carrier tape base using any suitable process, such as ultrasonic welding, adhesive bonding, thermocompression bonding, etc. According to one embodiment, the first and second cover tape pieces are secured to the carrier tape base simultaneously. In another embodiment, the carrier tape base and first and second cover tape pieces are integrally formed using an extrusion process. Referring to block 630, a gap is provided between the first and second cover tape pieces. It should be understood that a separate processing step will generally not be needed to create a gap between the cover tape pieces, as the cover tape pieces can be sized to provide the desired gap upon attachment to the carrier tape base. However, in an alternative embodiment, to create the gap, a single cover tape piece is first secured to the carrier tape, and then a center portion is cut from this single piece to create the first and second cover tape pieces separated by a gap.

[0039] The foregoing detailed description and accompanying drawings are only illustrative and not restrictive. They have been provided primarily for a clear and comprehensive understanding of the disclosed embodiments and no unnecessary limitations are to be understood therefrom. Numerous additions, deletions, and modifications to the embodiments described herein, as well as alternative arrangements, may be devised by those skilled in the art without departing from the spirit of the disclosed embodiments and the scope of the appended claims.

Claims

1. A carrier tape comprising: a base including an upper surface and a number of spaced apart pockets extending down from the upper surface, each pocket sized to receive a part; a first piece of cover tape secured to the base, the first piece of cover tape extending over a portion of each of the pockets; and a second piece of cover tape secured to the base, the second piece of cover tape extending over a portion of each of the pockets; wherein a gap exists between the first and second pieces of cover tape, the gap overlying the pockets.

2. The carrier tape of claim 1, wherein the first and second pieces of cover tape can be separated to an extent sufficient to allow access to one of the pockets.

3. The carrier tape of claim 1, wherein a center of the gap overlies a centerline of the base.

4. The carrier tape of claim 1, wherein each of the first and second pieces of cover tape is secured to the upper surface of the base.

5. The carrier tape of claim 1, wherein the first and second pieces of cover tape are each secured to the base by a process selected from a group consisting of ultrasonic welding, adhesive bonding, and thermocompression bonding.

6. The carrier tape of claim 1, wherein the carrier tape and the first and second pieces of cover tape are integrally formed using an extrusion process.

7. The carrier tape of claim 1, wherein the carrier tape comprises a material selected from a group consisting of polycarbonate, polystyrene, trilaminate polycarbonate with an acrylonitrile butadiene styrene (ABS) core, a homogeneous blend of two or more plastics, and paper.

8. The carrier tape of claim 1, wherein the first and second pieces of cover tape are each comprises of a material selected from a group consisting of polyester, polycarbonate, polystyrene, trilaminate polycarbonate with an ABS core, a homogeneous blend of two or more plastics, and paper.

9. The carrier tape of claim 1, wherein the number of spaced-apart pockets comprises a first row of pockets, the carrier tape further comprising: at least a second row of spaced apart pockets disposed on the base adjacent the first row of pockets; wherein the first and second cover tape pieces can be separated to an extend sufficient to allow access to at least one pocket in the first row and one pocket in the second row.

10. A method comprising: providing a base including an upper surface and a number of spaced-apart pockets extending down from the upper surface, each pocket sized to receive a part; securing a first piece of cover tape to the base, the first cover tape piece extending over a portion of each of the pockets; and securing a second piece of cover tape to the base, the second cover tape piece extending over a portion of each of the pockets; wherein a gap is provided between the first and second pieces of cover tape, the gap overlying the pockets.

11. The method of claim 10, wherein the first and second pieces of cover tape can be separated to an extent sufficient to allow access to one of the pockets.

12. The method of claim 10, wherein a center of the gap overlies a centerline of the base.

13. The method of claim 10, wherein each of the first and second pieces of cover tape is secured to the upper surface of the base.

14. The method of claim 10, wherein each of the first and second pieces of cover tape is secured to the base along a bond line extending respective lengths of the base and cover tape pieces.

15. The method of claim 14, wherein the bond line for each of the first and second pieces of cover tape is formed by a process selected from a group consisting of ultrasonic welding, adhesive bonding, and thermocompression bonding.

16. The method of claim 10, wherein the first and second pieces of cover tape are secured to the base simultaneously.

17. The method of claim 10, wherein the base and the first and second pieces of cover tape are integrally formed using an extrusion process.

18. The method of claim 10, wherein the base comprises a material selected from a group consisting of polycarbonate, polystyrene, trilaminate polycarbonate with an acrylonitrile butadiene styrene (ABS) core, a homogeneous blend of two or more plastics, and paper.

19. The method of claim 10, wherein the first and second pieces of cover tape are each comprises of a material selected from a group consisting of polyester, polycarbonate, polystyrene, trilaminate polycarbonate with an ABS core, a homogeneous blend of two or more plastics, and paper.

20. The method of claim 10, wherein the number of spaced-apart pockets comprises a first row of pockets and the base further comprises: at least a second row of spaced apart pockets disposed on the base adjacent the first row of pockets; wherein the first and second cover tape pieces can be separated to an extend sufficient to allow access to at least one pocket in the first row and one pocket in the second row.

21. A method comprising: spreading apart opposing portions of a first piece of cover tape and a second piece of cover tape, respectively, to provide access to a pocket, the pocket one of a number of spaced-apart pockets disposed on a carrier tape, the first and second pieces of cover tape secured to the carrier tape; and accessing the pocket.

22. The method of claim 21, wherein accessing the pocket comprises placing a part into the pocket or removing a part from the pocket.

23. The method of claim 22, wherein the part comprises an integrated circuit device.

24. The method of claim 21, wherein spreading apart opposing portions of the first and second pieces of cover tape comprises: inserting a separator tool into a gap between the first and second pieces of cover tape; and advancing the carrier tape to align the pocket with the separator tool, the separator tool spreading apart the opposing portions of the first and second cover tape pieces.

25. The method of claim 24, wherein the separator tool includes an aperture and the pocket is accessed through the aperture.

26. A system comprising: a source tape reel to hold a length of carrier tape, the carrier tape including a number of spaced-apart pockets, the carrier tape further including a first piece of cover tape and a second piece of cover tape, each of the first and second cover tape pieces secured to the carrier tape; and a separator tool, the separator tool to spread apart opposing portions of the first and second pieces of cover tape to provide access to one of the pockets.

27. The system of claim 26, wherein the carrier tape is advanced relative to the separator tool.

28. The system of claim 26, wherein the separator tool is advanced relative to the carrier tape.

29. The system of claim 26, further comprising a take-up reel to receive the length of carrier tape.

30. The system of claim 26, wherein the separator tool comprises: a body; and an aperture extending through the body, wherein the one pocket is accessed through the aperture.

31. The system of claim 30, wherein the body of the separator tool includes a leading portion that is sized and shaped to spread apart opposing inner edges of the first and second cover tape pieces to create a gap having a width at least equal to a dimension of the aperture.

32. The system of claim 26, further comprising a pick-and-place mechanism to insert a part into the one pocket or remove a part from the one pocket.