Abstract:
A chip carrier tape, which includes a tape member and a plurality of pockets, is provided. The plurality of pockets are formed in and along the tape member. Each of the pockets includes a first portion and a second portion. The first portion has a shape and size adapted to fit a first chip size therein. The second portion has a shape and size adapted to fit a second chip size therein. The first chip size differs from the second chip size. The first portion has a first pocket volume that is not part of the second portion, and the second portion has a second pocket volume that is not part of the first portion. There may be a second and different plurality of pockets formed in and along the tape member as well. Also a method of selling integrated circuit chips is provided.

Description:
TECHNICAL FIELD  
         [0001]    The present invention generally relates to tape and reel carriers used for shipping chips. In one aspect, it relates to a chip carrier tape adapted to carry multiple chip sizes.  
         BACKGROUND  
         [0002]    Some manufacturers produce semiconductor chips at one geographical location and have the chips packaged at another geographical location. Also, some manufacturers ship large quantities of packaged chips to other geographical locations. In such cases, the chips (packaged or unpackaged) are often delivered in a tape and reel package. A conventional tape and reel shipping package  40  is shown in FIG. 1. FIG. 2 shows an enlarged top view of a portion of a tape member  44  from FIG. 1. As shown in FIG. 2, the tape member  44  has a series of pockets  48  formed therein. Each pocket  48  has a shape and size designed to contain a certain size chip. In FIG. 2, one of the pockets  48  is shown with a chip  52  therein. After the chips  52  are placed in the pockets  48  of a tape member  44 , a film cover is often temporarily bonded to the tape member  44  to contain the chips  52  within the pockets  48 . Then with the chips  52  enclosed within the pockets  48 , the loaded tape member  44  is wound onto a reel  56 , as shown in FIG. 1, much like a film strip for a film projector is stored on a reel. The loaded reel  56  may then be boxed and/or stacked with other loaded reels to create a shipping package ready for delivery to another location.  
           [0003]    [0003]FIG. 3 shows a cross-section view of one of the pockets  48  shown in FIG. 2 taken along line  3 - 3 . FIG. 4 shows a cross-section view of the pocket  48  shown in FIGS. 2 and 3 taken along line  4 - 4 . FIG. 5 shows a cross-section view of the pocket  48  (shown in FIG. 2) with the chip  52  therein, as taken along line  5 - 5 . The tape member  44  has a row of holes  60  running along each side of the tape member  44  (see FIG. 2). These holes  60  may be used when feeding the tape member  44  through a machine (not shown) while loading/unloading chips to/from the tape member  44 , for example. These holes  60  may be useful for indexing the position of the pockets  48  and for engaging the tape member  44  with corresponding drive gears.  
           [0004]    In conventional tape members, the pockets are designed for a carrying a single chip in each pocket. Industry standards require that a pocket limits the movement of the chip within the pocket so that the chip will not be damaged during shipping. Even though a smaller chip may be placed in a pocket designed for a larger chip, the smaller chip may not be sufficiently constrained within the pocket to meet industry standards for constraining the chip during shipping to prevent damage to the chip. Thus, each chip design of a given size and shape usually requires its own set of tape and reel packages having pockets specifically shaped and sized for that chip design.  
         BRIEF SUMMARY OF THE INVENTION  
         [0005]    It would be more desirable and more economical to have a tape and reel package that can accommodate two or more different chip sizes and/or shapes. The problems and needs outlined above are addressed by certain aspects of the present invention. In accordance with one aspect of the present invention, a chip carrier tape is provided. The chip carrier tape includes a tape member and a plurality of pockets. The plurality of pockets are formed in and along the tape member. Each of the pockets includes a first portion and a second portion. The first portion has a shape and size adapted to fit a first chip size therein. The second portion has a shape and size adapted to fit a second chip size therein. The first chip size differs from the second chip size. The first portion has a first pocket volume that is not part of the second portion, and the second portion has a second pocket volume that is not part of the first portion. There may be a second and different plurality of pockets formed in and along the tape member as well.  
           [0006]    In accordance with another aspect of the present invention, a chip carrier tape is provided. This chip carrier tape includes a tape member and a plurality of pockets. The plurality of pockets are formed in and along the tape member. Each of the pockets has a cross shape formed from a first portion intersecting a second portion. The first portion has a shape and size adapted to fit a first chip size therein. The second portion has a shape and size adapted to fit a second chip size therein. The first chip size differs from the second chip size.  
           [0007]    In accordance with still another aspect of the present invention, a chip carrier tape is provided. This chip carrier tape includes a tape member and a plurality of pockets. The plurality of pockets are formed in and along the tape member. Each of the pockets has a first portion and a second portion. The first portion has a shape and size adapted to fit a first chip size therein, and the first portion is located at a first pocket depth. The second portion has a shape and size adapted to fit a second chip size therein, and the second portion is located at-a second pocket depth. The first chip size differs from the second chip size, and the first pocket depth differs from the second pocket depth.  
           [0008]    In accordance with yet another aspect of the present invention, a chip carrier tape is provided. This chip tape carrier includes a tape member and a plurality of pockets. The plurality of pockets are formed in and along the tape member. Each of the pockets includes a main portion and a first slotted portion. The first slotted portion intersects the main portion, and the first slotted portion is adapted to receive a tab insert therein. A first chip portion of the pocket is defined within the main portion when the tab insert is located within the first slotted portion. The first chip portion has a shape and size adapted to fit a first chip size therein. A second chip portion of the pocket is defined within the main portion and across the first slotted portion when the tab insert is absent from the first slotted portion. The second chip portion has a shape and size adapted to fit a second chip size therein. The first chip size differs from the second chip size.  
           [0009]    In accordance with another aspect of the present invention, a method of selling integrated circuit chips after the chips are fabricated is provided. The method includes the following step, the order of which may vary. First, a chip carrier tape is provided. The chip carrier tape includes a tape member and a plurality of pockets. The plurality of pockets are formed in and along the tape member. Each of the pockets includes a first portion and a second portion. The first portion has a shape and size adapted to fit a first chip size therein. The second portion has a shape and size adapted to fit a second chip size therein. The first chip size differs from the second chip size. The first portion has a first pocket volume that is not part of the second portion, and the second portion has a second pocket volume that is not part of the first portion. Second, at least one integrated circuit chip is loaded into at least one of the pockets. Third, the chip carrier tape, which is at least partially loaded, is delivered to a chip buyer.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    The above features of the present invention will be more clearly understood from consideration of the following descriptions in connection with accompanying drawings in which:  
         [0011]    [0011]FIG. 1 shows perspective view of a conventional tape and reel package;  
         [0012]    [0012]FIG. 2 shows an enlarged top view for a portion of a tape member of FIG. 1;  
         [0013]    [0013]FIG. 3 shows a cross-section view of a pocket from FIG. 2 taken along line  3 - 3 ;  
         [0014]    [0014]FIG. 4 shows a cross-section view of a pocket from FIG. 2 taken along line  4 - 4 ;  
         [0015]    [0015]FIG. 5 shows a cross-section view of a pocket from FIG. 2 taken along line  5 - 5 ;  
         [0016]    [0016]FIG. 6 shows a top view for a portion of a chip carrier tape in accordance with a first embodiment of the present invention;  
         [0017]    [0017]FIG. 7 shows a cross-section view of a pocket from FIG. 6 taken along line  7 - 7 ;  
         [0018]    [0018]FIG. 8 shows a cross-section view of the pocket from FIG. 6 taken along line  8 - 8 ;  
         [0019]    [0019]FIG. 9 shows a cross-section view of another pocket from FIG. 6 taken along line  9 - 9 ;  
         [0020]    FIGS.  10 - 12  show variations on FIG. 9;  
         [0021]    [0021]FIG. 13 shows a top view for a portion of a chip carrier tape in accordance with a second embodiment of the present invention;  
         [0022]    FIGS.  14 - 17  show cross-section views of a pocket from FIG. 13 taken along line  14 - 14 ,  15 - 15 ,  16 - 16 , and  17 - 17 , respectively;  
         [0023]    [0023]FIG. 18 shows a top view of a pocket for a chip carrier tape in accordance with a third embodiment of the present invention;  
         [0024]    [0024]FIGS. 19 and 20 show cross-section views for the pocket of FIG. 18 taken along lines  19 - 19  and  20 - 20 , respectively;  
         [0025]    [0025]FIG. 21 shows a top view for a portion of a chip carrier tape in accordance with a fourth embodiment of the present invention;  
         [0026]    FIGS.  22 - 27  show cross-section views of a pocket from FIG. 21 taken along line  22 - 22 ,  23 - 23 ,  24 - 24 ,  25 - 25 ,  26 - 26 , and  27 - 27 , respectively;  
         [0027]    [0027]FIG. 28 shows a pocket from FIG. 21 with two chips loaded therein;  
         [0028]    [0028]FIG. 29 shows a top view for a portion of a chip carrier tape in accordance with a fifth embodiment of the present invention;  
         [0029]    [0029]FIG. 30 shows a cross-section view of a pocket from FIG. 29 taken along line  30 - 30 ;  
         [0030]    [0030]FIG. 31 shows a top view for a pocket of a chip carrier tape in accordance with a sixth embodiment of the present invention;  
         [0031]    [0031]FIG. 32 shows a top view for a pocket of a chip carrier tape in accordance with a seventh embodiment of the present invention;  
         [0032]    [0032]FIG. 33 shows a top view for a pocket of a chip carrier tape in accordance with an eighth embodiment of the present invention; and  
         [0033]    [0033]FIG. 34 shows a cross-section view of a pocket from FIG. 33 taken along line  34 - 34 . 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0034]    Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout the various views, preferred embodiments of the present invention are illustrated and described. As will be understood by one of ordinary skill in the art, the figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of ordinary skill in the art will appreciate the many applications and variations of the present invention in light of the following description of the preferred embodiments of the present invention. The preferred embodiments discussed herein are illustrative examples of the present invention and do not limit the scope of the invention to the preferred embodiments described.  
         [0035]    The term “chip” is used herein to generically refer to packaged chips (e.g., assembled with lead frame pins or board pins) and/or chips not yet packaged. Generally, an embodiment of the present invention provides a chip carrier tape having pockets adapted to carry multiple chip sizes and/or shapes within each pocket. A first embodiment of the present invention is shown in FIGS.  6 - 12 . FIG. 6 shows a top view of a portion of a chip carrier tape  62  in accordance with the first embodiment. Each of the pockets  48  shown in FIG. 6 is formed in the tape member  44  and is adapted to retain up to two chips  52  (each of a different size) therein. FIG. 7 shows a cross-section view for one of the pockets  48  shown in FIG. 6 taken along line  7 - 7 . FIG. 8 shows a cross-section view for the pocket  48  shown in FIG. 6 taken along line  8 - 8 . As shown in FIGS. 7 and 8, the pockets  48  of the first embodiment have a depth that allows for two chips  52  to be retained within a pocket  48 . Referring to FIG. 6 again, another pocket  48  is shown with two chips  52  therein. FIG. 9 shows a cross-section view for the pocket  48  with chips  52  therein of FIG. 6 as taken along line  9 - 9 . Although not shown in FIGS. 6 and 9, FIG. 10 shows how a separator  68  may be included within the pocket  48  between the chips  52  to better retain the lower chip  52 . However, in some cases, such a separator  68  may not be needed. In another embodiment (not shown), the pocket  48  may be adapted to retain one chip size in two different orientations.  
         [0036]    [0036]FIGS. 11 and 12 show cross-section views of a pocket  48  in accordance with the first embodiment, each with only one chip  52  therein. In FIG. 11, due to the configuration of the upper portion  70 , the upper chip  52  is sufficiently retained whether the lower chip  52  is present or not. However in FIG. 12, when the lower chip  52  is alone within the pocket  48 , the pocket  48  will not sufficiently retain the lower chip  52  because it will be free to move into and about the upper portion  70  of the pocket  48 . Thus, as shown in FIG. 12, a spacer block  72  may be needed to better retain the lower chip  52  when the upper chip  52  is not present. The spacer block  72  may be a piece of plastic, for example, having dimensions similar to that of the upper portion  70  of the pocket  48  (i.e., similar to that of an upper chip size that the upper pocket portion  70  is designed to retain). Preferably, the spacer block  72  may have adhesive on its top side  74  so that it sticks to the film cover that goes over the top of the tape member  44  during shipping. Thus when the spacer block  72  is adhered to the film cover, it will be removed from the pocket  48  when the film cover is peeled away. In such case where the spacer block  72  is adapted to be adhered to the film cover, it may be feasible to have a smaller spacer block (not shown) (i.e., not of similar size to the upper pocket portion  70 ) as the adhesive will maintain the position of the spacer block above the lower chip. A loaded chip carrier tape  62  in accordance with the first embodiment may be wound onto a reel  56  just as with a conventional chip carrier tape  62  (see e.g., FIG. 1). Thus, the first embodiment may be implemented with existing reels.  
         [0037]    FIGS.  13 - 17  show a second embodiment of the present invention. FIG. 13 shows a top view of a portion of a chip carrier tape  62  in accordance with the second embodiment. Each of the pockets  48  shown in FIG. 13 has a cross shape formed from a first portion  76  intersecting a second portion  78 . The first portion  76  has a shape and size adapted to fit a first chip size therein. The second portion  78  has a shape and size adapted to fit a second chip size therein. The first chip size differs from the second chip size. One of the pockets  48  in FIG. 13 shows the placement of chips  52  in the pocket  48  in phantom lines. Each of the pockets  48  shown in FIG. 13 is formed in the tape member  44  and is adapted to retain one chip  52  at a time. Hence, a chip  52  retained in one of the pockets  48  shown in FIG. 13 at a given time may be of the first chip size or the second chip size. FIG. 14 shows a cross-section view for one of the pockets  48  shown in FIG. 13 taken along line  14 - 14 . FIG. 15 shows a cross-section view for the pocket  48  shown in FIGS. 13 and 14 taken along line  15 - 15 . FIGS. 16 and 17 show cross-section views for the pocket  48  shown in FIGS.  13 - 15  taken along lines  16 - 16  and  17 - 17 , respectively. If the depth of the pocket  48  were increased, the second embodiment could be modified to retain two or more chips in a stacked configuration.  
         [0038]    FIGS.  18 - 20  show a pocket  48  of a third embodiment of the present invention. FIG. 18 shows a top view of the pocket  48 , which is part of a chip carrier tape with multiple pockets (remainder not shown). FIGS. 19 and 20 show cross-section views for the pocket  48  shown in FIG. 18 taken along lines  19 - 19  and  20 - 20 , respectively. The pocket  48  in FIG. 18 has a cross shape formed from a first portion  76  intersecting a second portion  78  as in the second embodiment. But in addition, the third embodiment has a third portion  80  that intersects or overlaps with the first and second portions  76  and  78 . The first portion  76  has a shape and size adapted to fit a first chip size therein. The second portion  78  has a shape and size adapted to fit a second chip size therein. And, the third portion  80  has a shape and size adapted to fit a third chip size. The first, second, and third chip sizes differ from each other. Hence, the third embodiment can retain three different chip sizes with a single pocket design. The pocket  48  of the third embodiment is adapted to retain one chip at a time. However, if the depth of the pocket  48  were increased, the third embodiment could be modified to retain two or more chips in a stacked configuration.  
         [0039]    Referring again to FIGS. 2, 6, and  13 , note that these pockets  48  have a hole  82  formed therethrough. The hole  82  is an industry standard used by some equipment as an inspection hole to determine whether a chip  52  is present in the pocket  48 . In contrast, the pocket  48  of the third embodiment lacks such a hole  82 . Thus, an embodiment of the present invention may or may not have such a hole  82  formed in the bottom of the pocket  48 .  
         [0040]    Referring yet again to FIGS. 2 and 6, note that the tape members  44  shown in these figures have two rows of holes  60  for engagement with a drive sprocket (not shown), for example. But in contrast, the second embodiment shown in FIG. 13 has only one row of holes  60 . In another embodiment (not shown), the tape member  44  may have no row of holes. Industry standard EIA-481 (revision B) provides that on chip carrier tape having a width of 32 mm or larger, there should be two rows of sprocket holes  60 . For such cases, the industry standard states that a first row of sprocket holes  60  has round holes, and the second row of sprocket holes  60  has elongated holes. And for chip carrier tape  62  having a width less than 32 mm, there should be only one row of round holes  60 . Thus, an embodiment of the present invention may or may not have one or more rows of holes  60  extending along the tape member  44 , the number of rows (if used) may vary, and the shape of the holes may vary.  
         [0041]    FIGS.  21 - 28  show a fourth embodiment of the present invention. FIG. 21 shows a top view of a portion of a chip carrier tape  62  in accordance with the fourth embodiment. FIGS.  22 - 27  show cross-section views for one of the pockets  48  shown in FIG. 21 taken along lines  22 - 22 ,  23 - 23 ,  24 - 24 ,  25 - 25 ,  26 - 26 , and  27 - 27 , respectively. In the fourth embodiment, each of the pockets  48  shown in FIG. 21 has two levels of depth  70  and  84 , as best shown in FIGS. 23, 24, and  27 . The upper level  70  of the pocket  48  has a cross shape formed by three intersecting and overlapping portions, where each portion is adapted to retain a different chip size (as in the third embodiment of FIGS.  18 - 20 ). The lower level  84  of the pocket  48  has a cross shape formed by two intersecting portions, where each of these portions is adapted to retain a different chip size (as in the second embodiment of FIGS.  13 - 17 ). Hence, each pocket  48  of the fourth embodiment is adapted to retain five different chip sizes and is adapted to retain up to a total of two chips  52  at a time. FIG. 28 shows a top view of a pocket  48  in accordance with the fourth embodiment (remainder of tape member  44  not shown) having two chips  52 , each of a different size) loaded into the pocket  48 . The fourth embodiment therefore illustrates that the described embodiments may be mixed and/or combined to form other embodiments of the present invention.  
         [0042]    Although the orientation of intersecting portions in the pockets  48  described herein are parallel or orthogonal with respect to each other (see e.g., FIGS. 13, 18, and  21 ), this need not be the case. Such portions may intersect at any angle. With the benefit of this disclosure, one of ordinary skill in the art will realize many other possible embodiments of the present invention.  
         [0043]    FIGS.  29 - 30  show a fifth embodiment of the present invention. FIG. 29 shows a top view of a portion of a chip carrier tape  62  in accordance with the fifth embodiment. FIG. 30 shows a cross-section view for one of the pockets  48  shown in FIG. 29 taken along lines  30 - 30 . Each pocket  48  of the fifth embodiment is adapted to retain three different chip sizes having a common width dimension  88 , and is adapted to retain one chip  52  at a time. Each pocket  48  has two slot sections  90  that may be used to “adjust” the length of the pocket  48  (i.e., make it shorter or longer). In other alternative embodiments (not shown), there may be only one slot section  90  or there may be more than two slot section  90  per pocket  48 . Three of the pockets  48  shown in FIG. 29 have chips  52  therein (one chip  52  in each of the three pockets  48 ), and the chips  52  are different sizes. When the shortest chip  92  is loaded in a pocket  48 , a first insert tab  94  may be used to adjust the length of the pocket  48 . Similarly, when the mid-length chip  96  is loaded in a pocket  48 , a second insert tab  98  may be used to adjust the length of the pocket  48 . When the longest chip  100  is loaded in a pocket  48 , no insert tab is needed. If desired, an insert tab ( 94 ,  98 ) may have adhesive applied to its top side so that it adheres to the film cover, and/or adhesive applied to its bottom side so that it adheres to the bottom of the pocket  48 .  
         [0044]    As illustrated in FIG. 31, the sizes of the slot sections  90  are preferably the same to allow a single insert tab size to be used for any of the slot sections  90 . FIG. 31 shows a pocket  48  with a chip  52  therein and an insert tab  98  inserted into one of the slot sections  90  to retain the position of the chip  52  in accordance with a sixth embodiment of the present invention (remainder of the chip carrier tape  62  and other pockets  48  not shown). Hence, the pocket  48  of the sixth embodiment is adapted to retain four different chip sizes and is adapted to hold one chip  52  at a time.  
         [0045]    As illustrated in FIG. 32, the slot sections  90  do not necessarily have to be together (abutting each other). However, the slot sections  90  could also overlap each other. FIG. 32 shows a pocket  48  with a chip  52  therein and an insert tab  98  inserted into one of the slot sections  90  to retain the position of the chip  52  in accordance with a seventh embodiment of the present invention (remainder of the chip carrier tape  62  and other pockets  48  not shown). Hence, the pocket of the seventh embodiment is adapted to retain three different chip sizes and is adapted to hold one chip  52  at a time.  
         [0046]    [0046]FIGS. 33 and 34 shows a pocket  48  in accordance with an eighth embodiment of the present invention (remainder of the chip carrier tape  62  and other pockets  48  not shown). FIG. 33 shows a top view of the pocket  48 . FIG. 34 shows a cross-section view for the pocket  48  shown in FIG. 33 taken along line  34 - 34 . The pockets  48  of the eighth embodiment are similar to those of the fifth embodiment (see FIG. 29), but with an added portion at a second level  84  of pocket depth. Hence, the pocket  48  shown in FIGS. 33 and 34 is adapted to hold three different chip sizes (one chip  52  at a time) in the upper portion  70  of the pocket  48 , and is adapted to hold one chip size in the lower portion  84  of the pocket  48 . And thus, the pocket  48  shown in FIGS. 33 and 34 may retain up to two chips  52  at a time.  
         [0047]    It will be appreciated by those skilled in the art having the benefit of this disclosure that an embodiment of the present invention provides a chip carrier tape adapted to carry multiple chip sizes and/or shapes. It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive manner, and are not intended to limit the invention to the particular forms and examples disclosed. On the contrary, the invention includes any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art, without departing from the spirit and scope of this invention, as defined by the following claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.