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.

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.