KR101236687B1 - Component carrier and method for making - Google Patents

Abstract

The carrier tape includes a longitudinal strip having a plurality of part receiving pockets positioned therein. The pocket depth is greater than the thickness of the longitudinal strips. Adjacent pockets are spaced at a distance less than approximately five times the thickness of the longitudinal strip. The sidewalls separating adjacent pockets have a height greater than the pocket depth minus the height of the part the pocket is configured to receive. The carrier tape is made by providing a rotary tool and a nip roll having a rotary tool and a mating outer peripheral surface. The outer circumferential surface of the tool includes a protrusion for forming a pocket. The polymer web enters the nip between the tool and the nip roll and is embossed through the protrusion on the peripheral surface of the tool.

Carrier tape, pockets, longitudinal strips, polymer webs, nip rolls, peripheral surfaces, rotary tools

Description

Component carrier and manufacturing method {COMPONENT CARRIER AND METHOD FOR MAKING}

The present invention generally relates to a carrier tape having a plurality of longitudinally spaced pockets on the tape for receiving parts therein. In particular, the present invention relates to carrier tapes for very small parts and to methods for making such carrier tapes.

In general, carrier tapes are known which are used to hold and transport parts. For example, in the field of electronic circuit assembly, electronic components are conveyed from a source of components primarily to a specific location on a circuit board for attachment. The part including the surface mount part may be in many other forms. Specific examples include memory chips, integrated circuit chips, resistors, connectors, processors, capacitors, gate arrays, and the like.

In the electronics industry, rather than manually attaching each individual electronic component to a circuit board, it is sometimes called a "pick-up" that grasps the component at a specific location (i.e. from a carrier tape) and places it at another specific location (i.e. a printed circuit board). Expensive robotic placement machines known as "pick-and-place" are used. Gripping of the part is achieved through a vacuum pick-up device which mainly grips the top of the part by suction. Robotic placement equipment is typically programmed to repeat an accurate series of movements every cycle. In an electronic component assembly, the robotic equipment may be programmed to, for example, hold a memory chip and place it at a specific location on a circuit board. To ensure consistent operation of the robot placement machine, a continuous supply of electronic components at a given speed and position must be provided to the machine. Therefore, as each preceding and subsequent part, it is important that each part be located at the same position (i.e., the point where the robot placement machine grasps the part).

A common way to provide a continuous supply of electronic components to robotic placement equipment is to use carrier tape. Conventional carrier tapes generally comprise an elongated strip having a series of identical pockets formed at predetermined uniformly spaced intervals along the length of the tape. The pockets are each designed to receive electronic components therein. Generally, pockets are sized to fit a particular part. Component manufacturers typically load components in a series of pockets. After the parts are placed in the pockets, cover tape is applied over the long strips to hold the parts in each pocket. The loaded carrier tape is wound on a roll or reel and then conveyed from the component manufacturer to another manufacturer or assembler, where the roll of carrier tape may be mounted in some form of assembly equipment. The carrier tape is usually released from the roll and automatically advanced toward the robot pickup position. Advancement of the carrier tape is generally achieved using a series of through holes uniformly spaced along one or both edges of the elongated strip forming the carrier tape. The through hole receives the teeth of a drive sprocket that advances the tape towards the robot placement machine. As a result, the cover tape is peeled off from the carrier tape, and the part is removed from the pocket and then placed on the circuit board.

It is known to form a carrier tape using a rotating drum. The rotating drum has a plurality of molds disposed around the periphery. The mold may be a convex (i.e. male) or concave (i.e. female) mold and is sized to provide the desired final pocket dimensions taking into account the thickness of the tape, the depth of the pocket and the thermal shrinkage of the tape after molding. An exemplary method of making a carrier tape using a convex rotary mold is disclosed in US Pat. No. 5,800,722 to Kurasawa. In the production of embossed carrier tapes using convex rotary molds, the web of material is heated incrementally to the softening temperature and then guided through the periphery of the drum. The softened material is placed on the mold and is in hermetic contact with the entire side of the convex mold, except for the portion of the web located between adjacent convex molds. At the same time, the web is vacuum drawn against the mold to press the web into the space between adjacent molds.

Rotary molds used to form a vacuum as described above are generally constructed by stacking a plurality of drum sections as disclosed in US Pat. No. 5,800,772. When a plurality of drum sections are assembled together, a forming tool is created. The spaces between the drum sections allow the use of a vacuum to attract the molten web to form pocket features.

In the electronics sector, the trend toward smaller and smaller products requires the continued miniaturization of electronic components. There is a need to package small electronic components of about 1 mm (0.040 inches) long and less than 0.5 mm (0.020 inches) wide. One of the major problems in manufacturing carrier tapes for small parts is to consistently meet increasingly sophisticated dimensional accuracy and precision requirements. Current methods used to make forming tools have significant drawbacks in manufacturing carrier tapes for packaging small parts. For example, when forming a vacuum using a rotating drum, it becomes increasingly difficult to suck the web between and into smaller and more hermetically spaced molds. As a result, it is increasingly difficult to keep carrier tape feature dimensions within a given tolerance, and the feature of the carrier tape is not always accurately formed as a whole. When the dimensions of the carrier tape shape approach the same size as the thickness of the web, it becomes increasingly problematic to form the carrier tape with the required precision.

It is known to emboss a polymer web material between a nip roll and a mold tool formed of steel or chromium to make very small features into a polymer sheet. The thickness of the web exceeds the height of the feature on the tool, the feature is formed on the side of the web in contact with the tool feature, and the back side of the web (in contact with the nip roll) is completely flat and monotonous. Although such a structure applied to the carrier tape does not just use more polymer (which leads to more cost), the dimensions and reduced flexibility of the thick tape will also adversely affect the compatibility with many automation systems.

If the carrier dimensions are not maintained within precise tolerances, the shape of the carrier tape will not be accurately formed as a whole, and the parts may be trapped in the pockets and shaken and unstable in the pockets, moving to inaccurate positions or rolled over completely. Since it is impossible to accurately position the part in the pocket, an improperly positioned part of the pocket may fail to be ejected out of the pocket or may be improperly ejected when it is removed from the pocket. As a result, the improperly positioned portion may not be successfully mounted on a printed circuit board or the like.

In one aspect, the invention described herein provides a component carrier tape. In one embodiment according to the invention, the component carrier tape comprises a longitudinal flexible strip having a plurality of pockets positioned longitudinally on the longitudinal strip. The pocket is configured to receive the part therein. Each pocket has a depth from the top surface of the longitudinal strip that is greater than the thickness of the longitudinal strip. The sidewalls separating adjacent pockets are spaced at a distance less than approximately five times the thickness of the longitudinal strip, and the sidewall separating adjacent pockets have a height greater than the depth of the pocket minus the height of the part configured to accommodate the pocket.

In another embodiment according to the invention, the carrier tape comprises a longitudinal flexible strip having an upper surface and a lower surface opposite the upper surface. The plurality of pockets for receiving the parts are spaced along the strip and open through the top surface of the strip. Adjacent pockets are separated from each other by crossbars. The crossbar separates adjacent recesses by a distance less than approximately three times the thickness of the strip, and the top surface of the crossbar is substantially coplanar with the top surface of the strip. The plurality of projections extend from the bottom surface of the strip, each projection corresponding to one of the plurality of pockets.

In another aspect, the invention described herein provides a method for making a component carrier tape. In one embodiment according to the present invention, the method comprises providing a rotary tool having an outer peripheral surface and a nip roll having a mating outer peripheral surface opposite the outer peripheral surface of the tool. The outer circumferential surface of the rotary tool includes a series of protrusions for forming a plurality of longitudinally spaced part receiving pockets. The polymer web is introduced into the nip between the tool and the nip roll, and the polymer web is pressed between the tool and the nip roll to emboss the web through the protrusion on the peripheral surface of the tool. The embossed web is then removed from the tool.

1 is a partial perspective view of one embodiment of a carrier tape according to the present invention, wherein the optional cover has been partially removed to show the parts stored in the pocket of the carrier tape. Parts have been omitted from the subsequent pockets to more clearly show the interior of the pockets.

FIG. 2 is a cross-sectional view taken along line 2-2 of FIG.

3 is a schematic diagram of an exemplary process according to the present invention for producing the carrier tape of FIGS. 1 and 2.

4 is a photograph of a carrier tape made using a prior art process, showing an incompletely formed crossbar shape separating the adjacent pockets.

5 is a photograph of a carrier tape made using the process according to the present invention, showing a fully formed crossbar shape separating the adjacent pockets.

In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part thereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural and logical modifications may be made within the scope of the present invention. Accordingly, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the following claims.

The present invention provides a component holding or conveying device having a plurality of pockets formed therein that can be used for storing or conveying various types of components. In particular, the present invention provides a holding or conveying device having pockets formed very precisely for use in very small parts. In one embodiment, the present invention provides a longitudinal component carrier tape having a plurality of adjacently spaced pockets for storing, transporting and otherwise handling electronic or other components. Although an exemplary embodiment of a component carrier is described below with reference to a carrier tape for use with an electronic component, it will be appreciated that the component carrier may be configured for use with any form of material or material. For example, as may be used in a sample processing apparatus such as that described in US Patent Application No. 10 / 682,597 filed Oct. 9, 2003, the features and material of the component carrier may include a liquid sample material ( Or a sample material incorporated into a liquid).

Referring to the drawings, one embodiment of a carrier tape according to the present invention is shown in Figs. The carrier tape shown is particularly useful for the transport and storage of small electronic components by a forward mechanism. For the purposes of the present invention, small parts are those having at least one dimension on the order of about one millimeter (0.040 inches) or less.

The single flexible carrier tape 100 has a strip portion 101 that forms an upper surface 102 and a lower surface 103 opposite the upper surface 102. The strip portion 101 extends along the longitudinal edge surface 104, 106, one edge surface, and preferably both edge surfaces, and an aligned forward hole formed in one edge surface and preferably both edge surfaces. It includes columns of 108 and 110. Advance holes 108 and 110 include means for receiving advance mechanisms such as teeth of a sprocket drive (not shown) to advance carrier tape 100 toward a predetermined position.

A series of pockets 112 are formed in and spaced along the strip portion 101, with the pockets opening through the top surface 102 of the strip portion. Within a given carrier tape, each pocket 112 is typically substantially the same as the other pockets. Typically, the pockets 112 are aligned with each other and spaced equally. In an exemplary embodiment, each pocket 112 includes four sidewalls 114, each of which is generally perpendicular to each adjacent wall. The sidewall 114 extends adjacent to and downwards from the top surface 102 of the strip portion and abuts the bottom wall 116 to form a pocket 112. The bottom wall 116 is generally flat and parallel to the plane of the strip portion 101. The lateral sidewalls 114 of adjacent pockets 112 positioned longitudinally form a crossbar 117 that separates adjacent pockets 112.

Pocket 112 may be designed to match the shape and size of the part the pocket is intended to receive. Alternatively, pocket 112 may have a comprehensive design to easily accommodate components of various sizes and / or shapes. Although not specifically shown, the pocket may have more or fewer sidewalls than four shown in the preferred embodiment. In general, each pocket includes at least one sidewall 114 adjacent the strip portion 101 and extending therefrom and a bottom wall 116 adjacent the sidewall 114 to form a pocket 112. do. Thus, pocket 112 may have a circular, oval, triangular, pentagonal or other appearance. Each sidewall 114 has a slight draft (i.e., slope towards the center of the pocket) to facilitate insertion of the part and to assist in releasing the pocket from the mold or forming a die in the manufacture of the carrier tape. It may also be formed. In addition, the depth of the pocket can vary depending on the part the pocket is intended to receive. In addition, ledges, ribs, pedestals, bars, rails, appendages, and other similar structural features may be formed inside the pocket 112 to better store or support a particular component.

Although a single column of pockets 112 is shown in the figure, aligned pockets of two or more columns may also be formed along the length of the strip portion 101 to facilitate simultaneous transport of multiple parts. As described in US Pat. No. 4,298,120, the columns of pockets may be arranged parallel to each other with the pockets of one column, which are columns aligned with the pockets of adjacent columns. Alternatively, as described in US Pat. No. 4,724,958, pockets of adjacent columns may be offset from each other.

In the component carrier according to the invention, the sidewalls 114 of adjacent pockets 112 are separated by a distance of less than about 5 times the thickness of the web, preferably less than about 3 times the thickness of the web, separating the adjacent pockets 112. The upper edge of the wall 114 is substantially coplanar with the upper surface 102 of the strip portion 101. The height of adjacent sidewalls 114 is greater than the depth of the pocket minus the height of the component, preventing movement of the component between adjacent pockets. In some embodiments, the height of adjacent sidewalls is at least about 90% of the pocket depth, preferably at least about 95% of the pocket depth, and more preferably equals to the depth of the pocket 112. In some embodiments, the depth of the pocket 112 is greater than the thickness of the web forming the strip portion 101, and in other embodiments the depth of the pocket 112 is less than the thickness of the web forming the strip portion 101. to be. In either case, pocket 112 creates a corresponding protrusion on the bottom surface of strip 101. In some embodiments, at least one of the pocket length and the width of the pocket is less than 2 mm, preferably less than 1 mm. In another embodiment, the strip portion has a width of less than about 16 mm for multi-row embodiments, and a width of less than about 10 mm for single row embodiments. In yet another embodiment, the plurality of pockets 112 are spaced along the longitudinal strip at a pitch of about 2 mm or less.

 As long as the web has sufficient flexibility to allow it to be wound about the hub of the storage reel, the web forming the strip portion 101 may have any thickness. In some embodiments according to the present invention, the strip portion has a thickness of less than about 1 mm (40 mil), preferably less than about 0.5 mm (20 mil). In some embodiments, the strip portion has a thickness of less than about 0.25 mm (10 mil). The strip portion 101 may be selectively removed, colored or modified to be electrically dissipative or conductive. The electrically conductive material causes the charge to dissipate throughout the carrier tape, preferably to ground. This feature may prevent damage to components embedded in the carrier tape due to accumulated static charges.

The carrier tape 100 may optionally include the long cover tape 120. Cover tape 120 is applied over pocket 112 of carrier tape 100 to retain components therein. Exemplary component 118 is shown schematically in FIGS. 1 and 2. Cover tape 120 may also protect the part from dust and other contaminants that may enter the pocket. As best shown in FIGS. 1 and 2, the cover tape 120 is flexible, rests on part or all of the pocket 112, and the forward holes 108, 110 along the length of the strip portion 101. Are placed between columns. The cover tape 120 is releasably fixed to the top surface of the strip portion 101, which can then be removed to access the stored components. As shown, the cover tape 120 includes parallel longitudinal bonds 122, 124 bonded to the longitudinal edge surfaces 104, 106 of the strip 101, respectively. For example, pressure sensitive adhesives such as acrylic materials or heat activated adhesives such as ethylene vinyl acetate copolymer may be used to attach the cover to the edge surfaces 104, 106. Alternatively, the cover tape 120 may be fixed to the strip portion 101 by other means. Cover tape 120 may also be omitted, and the part is held in pocket 112 by, for example, an adhesive.

In one exemplary embodiment, the carrier tape according to the present invention is made by molding the pocket 112 into a sheet of polymeric material and winding the carrier tape on a reel to form a roll. Figure 3 schematically illustrates a manufacturing process and apparatus for use in the production of a component carrier tape according to the present invention. The rotary tool 200 has a structural outer circumferential surface 202. Surface 202 extends therefrom corresponding to various features to be formed in component carrier tape 100, such as component pocket 112, alignment features within pocket, boss or alignment holes for sprockets, and the like. ). For purposes of illustration, the protrusion 204 is greatly enlarged for the schematic illustration of FIG.

The nip roll 210 having the mating outer circumferential surface 212 is in contact with and opposed to the outer circumferential surface 202 of the rotary tool 200 such that the protrusion 204 presses against the surface 212 of the nip roll 210 to deform it. Let's do it. The outer peripheral surface 212 of the nip roll 210 is preferably covered with an elastomeric material. Suitable elastomeric materials include, but are not limited to, rubber, silicone, ethylene propylene diene monomers (EPDM), urethanes, teflon®, nitriles, neoprene, and fluoroelastomers. . In some embodiments, mating outer surface 212 of nip roll 210 has a Shore A hardness in the range of 20 to 100, preferably in the range of 50 to 90, depending on the material to be formed.

Melt processable polymer is transferred from the extruder 220 to the slot die apparatus 222. The melt processable polymer is transferred to the slot die apparatus 222 at or above its melt temperature (ie, the temperature at which it can be formed or molded). The web of polymer 230 is discharged from the die device 222 into the nip 240 between the rotary tool 200 and the nip roll 210. In some embodiments, it may be desirable for the polymer web 230 to be drop cast to the rotary tool 200 just before the nip roll 210 is formed in the nip 240. As the polymer web 230 is pressed between the rotary tool 200 and the nip roll 210 and embossed into the shape of the rotary tool 200, the mating outer surface 212 of the nip roll 210 deforms. The pressure applied to the web 230 by the mating nip roll 210 presses the molten resin of the web 230 into a small gap between the protrusions 204 of the rotary tool 200 (narrow pocket crossbar 117). Sufficient to provide a backside feature definition to the web 230 (ie, the feature is on the bottom surface 103 of the strip portion 101). Is formed). The pressure applied by the mating nip roll 210 will depend on a number of factors including processing speed, material viscosity, web thickness and dimensions, and spacing of protrusions 204 on the rotary tool 200.

The dimensions of the inlet polymer web 230 will be determined by the gauge and width of the carrier tape 100 to be formed. The thickness of the polymer web 230 and the pressure between the rotary tool 200 and the nip roll 210 are such that the thickness of the web 230 releasing the nip 240 forms the part pocket 112 of the carrier tape 100. It is preferably controlled to be smaller than the height of the protrusion 204. In a preferred embodiment, the polymer web 230 is transferred to the nip 240 at a thickness ranging from 5 mils (0.127 mm) to 20 mils (0.508 mm).

In some embodiments, it may be desirable for polymer web 230 to be transferred from die apparatus 222 to rotary tool 200 at or above its melt processing temperature. By providing the polymer web 230 to the rotary tool 200 at or above the melt processing temperature, the polymer can be suitably formed or replicated in the shape of the protrusion 204 on the rotary tool 200. . The temperature at which the polymer web 230 must be transferred from the die device 222 varies over a wide range depending on the speed and speed of the manufacturing line as well as the gauge and shape of the material to be formed. Although tool 200 is shown and described herein as a roll, it will be appreciated that tool 200 may alternatively be provided as any other rotatable structure that undergoes continuous web forming processing, such as a continuous belt.

After the nip 240 between the rotary tool 200 and the nip roll 210 retains the structure formed in the polymer web 230 and provides the web with mechanical stability, the temperature of the polymer web at a given point is preferably melt treated. Lowered below temperature. To aid in temperature control of web 230, rotary tool 200 and / or nip roll 210 may be heated or cooled as needed. The result of the process shown in FIG. 3 is an embossed web 250 that can be used to form the carrier tape 100 according to the present invention.

In the case of extrusion of the thermoplastic, the web of molten material is guided through the nip 240. As the embossed web 250 exits the nip 240, any suitable cooling means may be employed to cool the web and fully reinforce the material so that it may be removed from the rotary tool 200. Cooling may be achieved, for example, via convective air cooling, direct impingement of the air jet by a high pressure blower, water bath or spray, or cooling oven until the thermoplastic polymer is sufficiently solidified.

In the case of a polymerizable resin, the resin may be injected or pumped directly into a dispenser that is fed to the slot die device 222. In an embodiment where the polymer resin is a reactive resin, the method for producing the web further includes curing the resin in one or more steps. For example, depending on the nature of the polymerizable resin, the resin cures upon exposure to a suitable source of radiant energy, such as actinic radiation, ultraviolet light, visible light, or the like, to sufficiently cure the resin prior to removal from the rotary tool 200. May be Combinations of cooling and hardening may also be employed when curing the web as it comes off tool 200.

Suitable resin compositions for the component carrier tapes of the present invention are dimensionally stable, durable, and easily formable in any configuration. Suitable materials are 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 polyisobutene), modified poly (phenylene ether), polyurethane, polydimethylsiloxane, acrylonitrile butadiene styrene Resins and polyolefin copolymers, including but not limited to. In some embodiments, the material has a melting temperature in the range of 400 ° F. (204 ° C.) to 630 ° F. (332 ° C.) The material may be modified to be electrically dissipative or conductive. In this case, the material may comprise an electrically conductive material such as carbon black or vanadium pentoxide, which is interspersed in the polymer material or subsequently coated on the web. It may also include UV stabilizers or other additives.

In general, the rotary tool 200 may comprise any substrate suitable for forming by direct machining. Cleanly, suitable substrate machines that do not form or minimize burrs exhibit low ductility and low graininess and maintain dimensional accuracy after machining. Various machinable metals or plastics may be used. Suitable metals include aluminum, steel, brass, copper electroless nickel and alloys thereof. Suitable plastics include thermoplastic or thermoset materials such as acrylic or other materials. In some embodiments, the material forming the rotating tool 200 may comprise a porous material such that a vacuum may be applied through the material of the rotating tool 200 in combination with the nip roll 210.

The rotary tool 200 is preferably formed as a single sleeve with protrusions 204 for all desired carrier tape 100 features on a single sleeve. The sleeve may include pockets and protrusions for skiving to form their alignment features and, for example, sprocket holes. The method includes simultaneously thermoforming the pocket and the protrusions to provide good registration between the pockets and the protrusions.

The protrusions on the outer periphery 202 of the rotary tool 200 are preferably cut directly into the sleeve using a diamond tooling machine which is capable of shaping carbide or each protrusion with good precision. Moore Special Tool Company, Bridgeport, CT, Bridgeport, CT, and Aerotech Inc., Precitech, Keen, NH, Keene, NH, and Pittsburgh, PA, for that purpose. Aerotech Inc., Pittsburgh PA, manufactures suitable machines. Such machines typically include a laser interferometer-positioning device, a suitable example available from Zygo Corporation, Middlefield, CT, Middlefield, CT. Diamond tools for use are available from K & Y Diamond, Mooers, NY, Muir, NY, or Chardon Tool, Chardon, OH, Charden, Ohio.

The sleeve can be machined using techniques and methods known in the art to form the desired protrusion 204 thereon. For example, the protrusion surface corresponding to the part pocket sidewall 114 may be formed by redirecting the sleeve in a conventional lathe operation where the sleeve is switched and the cutter is in a fixed position. The protrusion surface corresponding to the component pocket crossbar 117 can be formed by holding the sleeve fixed and cutting the slot parallel to the axis of the sleeve. Additional protrusions, such as those for forming a post for skiving, may be formed in a manner similar to the formation of the protrusions used to shape the pockets. Advantageously, the protrusion 204 on the sleeve can be formed to simultaneously produce a plurality of carrier tapes. In particular, the pockets and other features for the plurality of carrier tapes can be manufactured on a single sleeve, and the web 250 is split after forming to isolate the individual carrier tapes.

Once the pocket 112 of the carrier tape 100 is ready, the forward holes 108, 110 punch the strip portion 101 or the longitudinal edge surface 104, as described, for example, in US Pat. No. 5,738,816. , 106), which are formed sequentially in a separation operation such as skiving a protrusion formed on one or both of them. Until parts are loaded onto the carrier tape 100, the carrier tape 100 is then wound around the reel 260 to form a supply roll for storage.

4 is a photograph of a conventional vacuum forming carrier tape formed during male tooling using conductive black polycarbonate resin. The low pocket crossbar is due to the limited flow of resin from the tooling to the narrow gap between the pockets.

5 is a photograph of a carrier tape formed using a static-baking black polystyrene resin in an extrusion replication process with a mating nip roll 210 in accordance with the present invention. The crossbar of the carrier is sufficiently formed. Certainly, the manufacturing method and apparatus of the present invention produce pocket crossbars that are considerably higher than standard vacuum forming pocket crossbars.

In experimental results, when the fully formed crossbar had a height of 0.631 mm, the average crossbar height achieved using conductive black polycarbonate in the standard vacuum forming process pocket was 0.107 mm, and the same material was used in the extrusion replication process of the present invention. The average crossbar height achieved using was 0.607 mm. Thus, the standard vacuum forming process produced a crossbar height equal to approximately 17% (0.107 mm / 0.631 mm) of the crossbar height where the crossbar height was sufficiently formed, and the extrusion replication process of the present invention produced approximately 96% (0.607 mm) of the sufficiently formed crossbar height. /0.631 mm).

Process example

The part carrier tape according to the invention was prepared using a static dissipative polystyrene resin filled with carbon black. The resin was fed to a single screw 2.5 inch (63.5 mm) Davis Standard extruder with a length / diameter (L / D) ratio of 30: 1. The elevated temperature profile was used for the extruder die zone and reached a final temperature of 450 ° F (232 ° C.). The molten polymer passed through a neck tube heated with a 10 inch (254 mm) wide film die block filled with a gap for a nominal gap of 0.070 inch (1.78 mm). The web melt coming out of the extruder die block is cast down into a nip formed by an aluminum forming tool and a nip roll covered with silicone rubber. Silicone rubber has a 75 Shore A hardness. Tool roll temperature was maintained at 100 ° F. (37 ° C.) and nip roll temperature was maintained at 70 ° F. (21 ° C.). After exiting the nip, the web is continuous around the curved surface of the tool as it is cooled by external compression with air cooling until it contacts the cold forming tool and reaches a temperature below the glass transition temperature of the material. The web was then removed from the tool and wound into a roll.

While specific embodiments have been shown and described herein for the purpose of describing the preferred embodiments, other and / or equivalent broadly varying embodiments, which are calculated to achieve the same purpose by those skilled in the art, are shown without departing from the scope of the invention. It will be appreciated that certain embodiments may be substituted for and described. Those skilled in the art will readily appreciate that the present invention may be practiced in a wide variety of embodiments. This application is intended to cover any adaptations and variations of the preferred embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.

Claims (23)

Component carrier tape, With longitudinal flexible strips, A plurality of pockets positioned longitudinally on the longitudinal strip and configured to receive the part therein; Each pocket has a depth from the top surface of the longitudinal strip, which is greater than the thickness of the longitudinal strip, And sidewalls separating adjacent pockets by a distance less than five times the thickness of the longitudinal strip, and sidewalls separating adjacent pockets having a height sufficient to prevent movement of components between adjacent pockets. Flexible carrier tape for storing and transporting parts by a forward mechanism, A longitudinal flexible strip having an upper surface and a lower surface opposite the upper surface; A plurality of pockets spaced along the strip and open through the top surface to receive the part, A plurality of protrusions extending from the bottom surface of the strip, Adjacent pockets are separated from each other by crossbars, the crossbars separating adjacent recesses by a distance less than three times the thickness of the strip, the top surface of the crossbar being flush with the top surface of the strip, each of the protrusions having a plurality of pockets Flexible carrier tape for storing and transporting parts by a forwarding mechanism, corresponding to one of the following. A method for producing an embossed carrier tape having a plurality of part receiving pockets longitudinally spaced on the front side, Providing a rotary tool having an outer peripheral surface; Providing a nip roll having a mating outer circumferential surface opposite the outer circumferential surface of the tool, Introducing a polymer web into the nip between the tool and the nip roll, Pressing the polymer web between the tool and the nip roll to emboss the web with a protrusion on the peripheral surface of the tool, Removing the embossed web from the tool, Wherein the outer circumferential surface comprises a series of protrusions for forming a plurality of longitudinally spaced part receiving pockets, the front side of the embossed carrier tape having a plurality of longitudinally spaced part receiving pockets. delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete

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