Patent Document

TECHNICAL FIELD  
       [0001]     Embodiments are generally related to lead frame and integrated circuit manufacturing processes and operations thereof. Embodiments are also related to reel-to-reel mechanisms.  
       BACKGROUND OF THE INVENTION  
       [0002]     Most electronic packages, which include sensors connected to input/output devices thereof, utilize leadframes, a PCB, or combinations thereof. Such electronic packages generally require that a conductors and/or insulators connect from a sensing element to the outside of the package for a customer to properly interface with the device. Leadframes provide customized configurations in which a designer can create many packages in order to meet a customer&#39;s overall need. Unfortunately, all of this customization must link in some electrical means to create a device.  
         [0003]     In a typical sensing device, an SOIC may be created to house the die and permit electrical contact for the next operation. In many leadframe designs, the central focus is a “plug”, which is the customer&#39;s means of connection to the sensing portion of the device. Common methods of connecting to leadframes including wire bonding and soldering techniques. Both of these connecting methods require that the leadframe be plated. Common plating material for wire bonding involves the use of gold, while tin is often utilized for soldering.  
         [0004]     A number of complications are involved in the use of leadframes. For example, leadframes require cleaning following stamping and prior to plating in order to remove excessive oils and contaminates. Leadframes also function as a conductor and require an insulator to allow a usable electronic connection. Leadframes additionally require a significant capital investment to produce the conductor. The ability of a leadframe to be manipulated into a desired package configuration is very limited because the method of production chosen typically involves stamping. The simplest leadframe would be flat and straight. Any deviation from the simple design requires significant effort to ensure that angles and bends are precise for not only the package configuration, but also interface with the overmold process.  
         [0005]     The over mold process provides the insulation characteristics for the circuit and also the structure required to hold the leadframe. The cost of the mold is greatly influenced not only by its dimensional configuration, but also by the ability to interface with the leadframe. The interface with the leadframe in the mold may be one of the driving factors of circuit costs, because of the consistency required to ensure repeatability, eliminate flash, and prevent leadframe movement. In such processes, 99.9% of the material required to create the electrical connection is wasted. Waste in such processes is found not only what is thrown away via the stamping process, but also, in what is required to create the leadframe.  
         [0006]     Leadframes do not optimize material thickness for electrical properties in sensor devices. The thickness driver focuses on requirements for the plug out configuration in the device and necessary requirements involved in the stamping process. Little leeway exists for the package designer to meet the plug connection requirements of the customer while still optimizing the conductor thickness for the sensor, without creating additional electrical joints or increasingly complicated leadframe configuration processes. For example, a customer may require a 0.032″ thick plug. The electrical requirements of the device mandate only 0.005 thick materials. Thus, the electrical properties involved in a stamping manufacturing process may be impossible to achieve due to stamping constraints, as well as handling complications.  
         [0007]     A PCB (Printed Circuit Board) has become an economical means for producing circuitry utilizing copper foil, fiberglass, and resin to create the insulated conductor. This method maximizes the efficiency of the conductor when compared to the leadframe, because the conductor material requirement comes closer to meeting the electrical requirements required by the circuit. Yet, PCB issues include the cost of the board when the size becomes large. In addition, the conductor is merely flat. Also, a requirement exists to provide an interconnect to the PCB in order to interface with the customer&#39;s I/O. Due to the standardization of PCBs, the designer must attempt to optimize the area within the panel. Additionally, routing may be required, not only to give the PCB dimensional size, but also to disconnect from the panel. Typically, additional structures are required to not only to hold the PCB in place, but also to maintain the plug.  
         [0008]     It can therefore be very difficult to separate leadframes from PCBs, because of the interaction required to configure sensing devices. A unique method of creating conductors for electronic packages is the MID (molded interconnected device) technique. Such a method creates the conductor and the insulator by utilizing two different plastics in which one can be plated, while the second plastic (i.e., the insulator) can be molded over the plateable plastic, creating a pattern for the circuitry.  
         [0009]     Unfortunately, such process requires two molds to create the circuitry. The capital investment of such processes is similar to the leadframe method wherein the conductive plastic is inserted into a mold and all the variation of both conductive plastic and the mold from the second plastic must interface precisely. After the over molding process, the package is plated to create the electrical traces required for the circuitry. The precision of such traces is equal to the precision of the mold, which interfaces to plastics. Although the MID technique permits increasingly complicated traces in leadframe designs, a number of issues are related to the MID method.  
         [0010]     MID operations typically require two molds, along with a high precision for interfacing the two molds to obtain higher resolution of traces. A great deal of handling is also required to produce the circuitry. MID operations also typically lack automation, which is desirable in order to provide manufacturing ease of assembly.  
         [0011]     A second plastic circuitry method utilizes a photomask to develop a circuit. This only requires one mold to produce the substrate. The creation of the other circuitry is accomplished by photo, masking, and etching techniques. This method permits,  3 -D circuitry not only for one mold, but also permits the change of the circuitry without changing the plastic substrate configuration. This key flexibility permits multiple circuit configurations to be created from one base package without the complications of additional capital expenditure or process modification. Circuitry is merely altered by providing a new photomask. Another benefit of this process is a high resolution in the trace width.  
         [0012]     Issues with this process include lack of automation, and a requirement for handling between processes to create the circuitry. Angles are also required to configure the circuitry in a 3-D mode. Complications can also be encountered when creating multiple parts and a panel assembly, while still maintaining the circuitry resolution that would be seen on a single part in high volumes.  
       BRIEF SUMMARY OF THE INVENTION  
       [0013]     The following summary of the invention is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the various aspects of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole.  
         [0014]     It is, therefore, one aspect of the present invention to provide improved leadframe and IC manufacturing processes and operations thereof.  
         [0015]     It is another aspect of the present invention to provide for reel-to-reel manufacturing methods and systems.  
         [0016]     The aforementioned aspects of the invention and other objectives and advantages can now be achieved as described herein. Reel-to-reel manufacturing methods and systems are disclosed herein. In general, one or more parts (e.g., plastic parts) can be transported on a carrier for manufacturing of a final product based initially on the part. A reel-to-reel mechanism is provided comprising one or more reels associated with the carrier, such that the part can be spooled and unspoiled upon the one or more of the reels prior and subsequent to a performance of a manufacturing operation upon the part. A plurality of manufacturing operations can then be subsequently upon the part utilizing the reel-to-reel mechanism to create a final product based upon the part initially subject to the manufacturing operations.  
         [0017]     The embodiments disclosed herein therefore describe a manufacturing system using plastic circuitry fabrication techniques and reel-to-reel processes. The reel-to-reel is found in a number of leadframe devices to reduce the cost of handling and secondary operations as it associates with plating and plastic molding. This innovation centers on circuitry created in plastic and providing automation to not only reduce the costs but reduce the variation.  
         [0018]     In a reel-to-reel process, the individual units or packages, which are a portion of the overall device, are transported on a carrier allowing the numerous units to be rolled into a reel. As described herein, the reeling and unreeling of units is only required if there is a break in the manufacturing process. Theoretically, an entire string of units may be processed from the beginning of the manufacturing process of the device to the end on a single carrier without interruption. The speed of this process is dictated by the slowest process. The complications of creating a single line are due to the investment of capital, the utilization of machinery, and floor space. As a result, the reel-to-reel method permits quick setups and easy transportation of units through the processes, because there are tooling points, which allow orientation.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]     The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.  
         [0020]      FIG. 1  illustrates a block diagram illustrative of a plastic molding operation and a reel-to-reel mechanism, which can be implemented in accordance with a preferred embodiment of the present invention;  
         [0021]      FIG. 2  illustrates a block diagram illustrative of plating and photo circuit layout operations in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention;  
         [0022]      FIG. 3  illustrates a block diagram illustrative of stripping and build-up operations in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention;  
         [0023]      FIG. 4  illustrates a block diagram illustrative of a component placement operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention;  
         [0024]      FIG. 5  illustrates a block diagram illustrative of a testing operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention;  
         [0025]      FIG. 6  illustrates a block diagram illustrative of a packaging operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention;  
         [0026]      FIG. 7  illustrates a block diagram illustrative of a final testing operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention;  
         [0027]      FIG. 8  illustrates a block diagram illustrative of packing and shipping operations, in accordance with a preferred embodiment of the present invention;  
         [0028]      FIG. 9  illustrates a block diagram illustrative of a plastic molding operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention;  
         [0029]      FIG. 10  illustrates a block diagram illustrative of an over-mold operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention;  
         [0030]      FIG. 11  illustrates a block diagram illustrative of a plating operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention;  
         [0031]      FIG. 12  illustrates a block diagram illustrative of a build-up operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention;  
         [0032]      FIG. 13  illustrates a block diagram illustrating in greater detail the build-up operation depicted in  FIG. 12 , in accordance with an alternative embodiment of the present invention;  
         [0033]      FIG. 14  illustrates a block diagram illustrative of a component placement operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention;  
         [0034]      FIG. 15  illustrates a block diagram illustrative of a testing operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention;  
         [0035]      FIG. 16  illustrates a block diagram illustrative of a packaging operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention;  
         [0036]      FIG. 17  illustrates a block diagram illustrative of a final testing operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention; and  
         [0037]      FIG. 18  illustrates a block diagram illustrative of packing and shipping operations, in accordance with an alternative embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]     The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment of the present invention and are not intended to limit the scope of the invention.  
         [0039]      FIG. 1  illustrates a block diagram of a system  100  that includes a plastic molding operation and a reel  120  of a reel-to-reel mechanism, which can be implemented in accordance with a preferred embodiment of the present invention. Note that FIGS.  1  to  8  depicted and described herein represent a preferred embodiment, while FIGS.  9  to  18  represent an alternative embodiment. In FIGS.  1  to  8 , identical or similar parts are generally indicated by identical reference numerals. FIGS.  1  to  8  represent sequential manufacturing operations, beginning with the operations of system  100  and continuing to the operations of system  200  of  FIG. 2 , and so forth. Note that in general,  FIGS. 1-8  represent a photo plating process of producing a circuit utilizing a reel to reel system, while  FIGS. 9-18  utilize the MID or two mold method with the reel to reel process.  
         [0040]      FIG. 2  illustrates a block diagram of a system  200  illustrative of plating and photo circuit layout operations in association with reel  120  of a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention. System  200  can be implemented partially within an area  206 , which can constitute a proprietary portion of the manufacturing process.  
         [0041]     System  100  includes a wire  102  (i.e., wire A) and a wire  104  (i.e., wire B) which are associated respectively with carriers  106  and  108 , which may be formed from wire extending from wires  102  and  104 . It can be appreciated that although in this context, wire is discussed with respect to a preferred embodiment, carriers can also be formed from other materials, such as Mylar, stamping, plastic links, and so forth. For illustrative purposes, however, wire is discussed herein. Carriers  106  and  108  are linked to a plastic molding module  110 , which can be fed plastic material  116  provided by a plastic manufacturer  118 . Plastic molding module  110  implements a plastic molding operation. Following processing of the plastic molding operation via module  110 , plastic parts  112  and  114  are generated and as output and carried upon carriers  106  and  108 . Parts  112  and  114  can then be spooled on reel  120 . Note that spooling via reel  120  is an optional operation and can be used to permit linkage to the next process, which is depicted in process  200  of  FIG. 2 . The process depicted in  FIG. 1  continues in  FIG. 2 , as indicated by continuation block  122 .  
         [0042]     Note that the term “module” as utilized herein can refer both to a physical module (e.g., hardware or manufacturing components) and/or a software or process module that performs a particular task based upon a set of particular instructions stored in a memory of a data-processing system, such as a computer, and processible via a processor, such as, for example, a microprocessor or central processing unit (CPU). Thus, the term “module” can refer to a collection of routines and data structures that can implement a particular task or abstract data types, and can also be referred to as a “software module”.  
         [0043]     Software modules can be composed of two parts. First, a software module may list the constants, data types, variable, routines and the like that that can be accessed by other modules or routines. Second, a software module can be configured as an implementation, which can be private (i.e., accessible perhaps only to the module), and that contains the source code that actually implements the routines or subroutines upon which the module is based. Thus, for example, the term module, as utilized herein can refer to software modules or implementations thereof. Such modules can be utilized separately or together to form a program product that can be implemented through signal-bearing media, including transmission media and recordable media.  
         [0044]     The term “module” can also refer, however, to a self-contained hardware component that provides a complete function into a system and be interchanged with and/or function in association with other modules that provide other functions. Such modules can be referred to also as “hardware modules”. The term “module” as utilized herein can thus refer to both hardware or software modules and/or a combination thereof.  
         [0045]     An un-reel operation can be implemented via reel  120  and the bare parts  112  and  114  are carried along the carriers, as indicated at time T 2 . Parts  112  and  114  can be subject to a plating operation via a plating module  204 . In the example of  FIG. 2 , copper can be plated for a base. Note that copper is referenced only as an example with respect to particular embodiments of the prevent invention. Other materials may be plated in place of copper. The plating operation implemented via plating module  204  can be based on a reel-to-reel or batch manufacturing operation. As indicated at time T 3 , parts  112  and  114  are now plated and can thereafter, as depicted at time T 4 , be spooled on reel  120 . Reeling via reel  120  is an optional operation and may be utilized to permit linkage to the next processes, which are indicated at times T 5  and T 6 .  
         [0046]     The plated parts can be unreeled (i.e., if required) utilizing reel  120 , as indicated at time T 5  and thereafter subject to a photo-circuit layout operation via a photo-circuit layout module  212 . The photo process can be created utilizing a CAD file. Masking patterns can be accomplished with one or multiple reel processing, depending upon design choices. As indicated at time T 6 , parts  112  and  114  can be subject to a pattern created thereon in the form of a mask, which may be a positive or a negative mask. Note that a stripping module can be optionally implemented for stripping parts  112  and  114  to reveal a circuit pattern thereof, as also indicated at time T 6 . Thereafter, as indicated at time T 7 , parts  112  and  114  can be subject to a reeling operation via reel  120  (i.e., again, if required). The process then continues, as indicated at continuation block  216 , which is also depicted in  FIG. 3 .  
         [0047]      FIG. 3  generally illustrates a block diagram illustrative of a process  300  that includes stripping and build-up operations in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention. Thus, the process continues, as indicated at continuation block  216 . Reel  120  can be utilized to un-reel parts  112  and  114  as indicated at time T 8 . Parts  112  and  114  can then be subject to plating via plating module  204 . The parts are then indicated following the plating operation via plating module  204 , as indicated at time T 9 . Next, as indicated at time T 10 , a build-up process can be implemented via a build-up module  307 . After the base plating occurs, a build-up operation can be implemented to create a final usable circuit upon parts  112  and  114  via a build-up module  307 .  
         [0048]     In the example depicted in  FIG. 3 , nickel and gold are added. Such a build-up operation may permit a continuous reel to attain the final plated configuration. Alternatively, multiple unreeling/reeling operations can be implemented utilizing reel  120 . Plating may occur via bulk or reel-to-reel processing, depending upon desired embodiments. All plating processes such as etching, cleaning, rinsing, and plating can be included as part of the plastic metallization processes depicted in  FIGS. 1-8 . Following a reeling operation via reel  120  (i.e., if required), the process continues, as indicated at continuation block  310 .  
         [0049]      FIG. 4  illustrates a block diagram illustrative of process  400  that includes a component placement operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention. In  FIG. 4 , an un-reeling operation may be implemented (i.e., if required) via reel  120 . As indicated at time Tar, parts  112  and  114  can continue to be carried toward the next processing step, which involves component placement, via a component placement module  404 .  
         [0050]     Components can be attached to the plastic lead frame structure of parts  112  and/or  114  by a variety of possible techniques to establish electrical connections thereof. Recall that parts  112  and  114  can be configured as plastic lead frames. Such techniques can include, for example, soldering, conductive adhesive techniques, ultrasonic welding, and/or pressure contacts. The components are indicated thereafter integrated with and/or connected to parts  112  and  114  at time T 12 , immediately prior to reeling (i.e., if required) via a reel  120 . The process then continues, as indicated at continuation block  408 .  
         [0051]      FIG. 5  illustrates a block diagram illustrative of a system  500  involving a testing operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention. An un-reeling operation can be implemented via reel  1202  (i.e., if required). Parts  112  and  114  are shown in  FIG. 5  at time T 13 , prior to implementation of an optional testing operation via a testing module  504 . Tests performed via testing module  504  can include, for example, function and continuity testing. Parts  112  and  114  are thereafter shown in  FIG. 5  at time T 14 , prior to reeling via a reel  120  (i.e., if required). The process then continues, as indicated at block  508 .  
         [0052]      FIG. 6  illustrates a block diagram illustrative of a system  600  that includes a packaging operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention. An un-reeling operation can be implemented via reel  120 . Parts  112  and  114  are shown in  FIG. 6  at time T 15 , prior to implementation of a packaging operation via a packaging module  604 . Packaging can take into account a variety of operation forms, including, for example, sealing, thermal packaging, structure built-in seals, and/or vibration isolation. Packaging module  604  can implement more than one packaging operational step and may require that reel  120  be spooled and re-spooled. Parts  112  and  114  are thereafter depicted in  FIG. 6  at time T 16  prior to optional reeling via reel  120 . The process can then continue, as indicated at continuation block  608 .  
         [0053]      FIG. 7  illustrates a block diagram illustrative of a system  700  that includes a final testing operation in association with a reel-to-reel mechanism, in accordance with a preferred embodiment of the present invention. Reel  120  can be utilized to implement an un-reeling operation (i.e., if required). Parts  112  and  1   14  are depicted in  FIG. 7  at time T 17  prior to subjugation to a final testing operation, which can be implemented via a testing module  704 . A number of tests are required prior to shipment. Such a testing operation can, however, be optionally performed following a singulation operation, which is depicted subsequently in  FIG. 8 . Parts  112  and  114  are shown in FIG. at time T 18  following testing module  704  and prior to reeling via reel  120 . Note that reeled parts can be shipped to a customer interface with the customer&#39;s automated equipment. The process then continues, as indicated at block  708 .  
         [0054]      FIG. 8  illustrates a block diagram illustrative of a system  800  that includes packing and shipping operations, in accordance with a preferred embodiment of the present invention. Parts  112  and  114  are shown in  FIG. 8  at time Tag, prior to implementation of a singulation operation via a singulating module  802 . Note that an optional “OR” block  801  is also indicated in  FIG. 8 , which indicates that the implementation of singulation module  802  is optional. The parts (e.g., part  112  depicted at time T 20 ) can simply be directly subject to a packaging operation via packaging module  804  following by shipping via a shipping module  808 .  
         [0055]     Note that in FIGS.  1  to  8 , systems  100 - 800  illustrated therein can constitute an overall system in which parts are reeled/un-reeled, coiled/uncoiled, spooled/unspoiled in and out of various processes implemented respectively via various modules. The desire of the embodiment of FIGS.  1  to  8  is to accomplish -an entire manufacturing process with the fewest reel-handling operations as possible. The reels depicted in FIGS.  1  to  8  can be implemented as multiple reels, a single reel, or only two reels, depending upon design constraints and goals. For example, instead of utilizing a single reel  120 , one or more reels may also be utilized to accomplish both reeling and unreeling operations. The use of a single or multiple reel configurations again depends on the goals of the manufacturing operation.  
         [0056]      FIG. 9  illustrates a block diagram illustrative of a system  900  that includes a plastic molding operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention. In FIGS.  9  to  18 , identical or similar parts are generally indicated by identical reference numerals. FIGS.  9  to  18  represent sequential manufacturing operations, beginning with the operations of system  900  and continuing to the operations of system  1000  of  FIG. 10 , and so forth.  
         [0057]     System  900  includes a wire  902  (i.e., wire A) and a wire  904  (i.e., wire B) which are associated respectively with carriers  903  and  905 , which may be formed from wire extending from wires  902  and  904 . It can be appreciated that although in this context, wire is discussed with respect to a preferred embodiment, carriers can also be formed from other materials, such as Mylar, stamping, plastic links, and so forth. For illustrative purposes, however, wire is discussed herein. Carriers  903  and  905  are linked to a plate-able plastic molding module  906 , which can be fed plastic material  911  provided by a plastic manufacturer  908 . Plastic material  911  is provided as raw material, which may be in the form of thermoplastic or thermo set material.  
         [0058]     Plastic molding module  906  generally implements a plastic molding operation. Following processing of the plastic molding operation via module  906 , plastic parts  1112  and  1114  are generated as output and carried upon carriers  903  and  905  as indicated at time T 1  of  FIG. 9  Parts  1112  and  1114  can then be spooled utilizing reel  910 . Note that spooling via reel  910  is an optional operation and can be used to permit linkage to the next process, which is depicted in system  1000  of  FIG. 10 . The process depicted in  FIG. 9  continues in  FIG. 10 , as indicated by continuation block  912 .  
         [0059]      FIG. 10  illustrates a block diagram illustrative of a system  1000  that includes an over-mold operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention. Bare parts  1112  and  1114  are illustrated in  FIG. 10  at time T 2 , following un-reeling via reel  910  (i.e., if required). Parts  1112  and  1114 , which at this point in the process are configured as bare plastic lead frame structures can then be subject to an over-molding operation via a molding module  1004 , wherein the plastic of parts  1112  and  1114  is over-molded with non-plateable plastic. Parts  1112  and  1114  are thereafter indicated at time T 3  with a second plastic over-mold. Parts  1112  and  1114  can then be spooled on reel  910 . Note that spooling via reel  1006  is an operation operational and may be used to permit linkage to the next process, which continues in  FIG. 11 , as indicated at continuation block  1008  of both  FIGS. 10 and 11 .  
         [0060]      FIG. 11  illustrates a block diagram illustrative of a system  1100  that includes a plating operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention. Parts  1112  and  1114  are depicted in  FIG. 11  at time T 4 , following an un-reeling operation implemented via reel  9102  (i.e., if required). Parts  1112  and  1114  can then be subject to a plating operation, which may be a reel-to-reel or batch plating operation implemented via a plating module  1104 . In the example of  FIG. 11 , copper may be plated. It can be appreciated, of course, that other metals can be plated in place of or in addition to copper. The plated circuitry is thereafter indicated on parts  1112  and  1114  at time T 5 . Thereafter, if required, a reeling operation can be implemented via reel  910 . The process can then continue, as indicated at continuation block  1108 .  
         [0061]      FIG. 12  illustrates a block diagram illustrative of a system  1200  that includes build-up operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention.  FIG. 13  illustrates a block diagram illustrating a system  1300  that shows in greater detail the build-up operation depicted in  FIG. 12 , in accordance with an alternative embodiment of the present invention. Reel  910  may be utilized to implement an un-reeling operation.  FIG. 12  depicts parts  1112  and  1114  at time T 6 , immediately prior to the implementation of a build-up operation or process via a build-up module  1204 . After base plating, a build-up operation may be implemented to create a final usable circuit upon parts  1112  and  1114 .  
         [0062]     The process continues from  FIG. 12  to  FIG. 13 , as indicated at continuation block  1206 . In the scenario of  FIGS. 12 and 13 , the build-up process implemented via build-up module  1204  can result in the addition of nickel and gold, as respectively indicated at time T 7  and time T 8 . Such a build-up may allow one continuous reel to attain the final plated configuration or multiple unreeling/reeling operations, depending upon design constraints. Plating may be accomplished by bulk or reel-to-reel processing. All plating processes, such as etching, cleaning, rinsing and plating can be included in the plastic metallization operations of  FIGS. 11-13 . A reeling operation can be implemented via reel  9102  (i.e., if required). The process then continues to  FIG. 14 , as indicated at continuation block  1304 .  
         [0063]      FIG. 14  illustrates a block diagram illustrative of a system  1400  that includes a component placement operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention. Parts  1112  and  1114  are depicted in  FIG. 14  at time T 9 , following implementation (i.e., if necessary) of an un-reeling operation via reel  910 . Parts  1112  and  1114  can then be subject to a component placement operation via a component placement module  1404 .  
         [0064]     Components can be attached to the plastic lead frame structure of parts  1112  and  1114  by a variety of means to establish electrical connections thereof, including techniques such as soldering, conductive adhesion, ultrasonic welding, pressure contact and the like. Parts  1112  and  1114  are next shown at time T 10 , prior to implementation of a reeling operation (i.e., if required) via reel  1910 . The process can then continue to  FIG. 15  as indicated at continuation block  1408 .  
         [0065]      FIG. 15  illustrates a block diagram illustrative of a system  1500  that includes a testing operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention. Parts  1112  and  1114  are depicted in  FIG. 15  at time T 11 , following a reeling operation (i.e., if required) implemented via reel  1502 . Parts  1112  and  1114  can then be subject to a testing operation via a testing module  1504 . Testing operations implemented via testing module  1504  can include, for example, tests such as functionality and continuity tests. Parts  1112  and  1114  are then depicted in  FIG. 15  at time T 12 , prior to implementation of an un-reeling operation via reel  910 . The process then continues to  FIG. 16 , as indicated at block  1508 .  
         [0066]      FIG. 16  illustrates a block diagram illustrative of a system  1600  that includes a packaging operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention. An un-reeling operation (i.e., if required) can be implemented via reel  910 . Thereafter, at time T 12 , parts  1112  and  1114  are depicted in  FIG. 16  prior to implementation of a packaging operation  1604  via a packaging module  1604 .  
         [0067]     Packaging via packaging module  1604  can take into account a variety of packaging operations including, but not limited to thermal packaging, structure packaging, built-in seals, and vibration isolation. Such an operational package may include more than one manufacturing step and can additionally require the reel at issue to be unspoiled and re-spooled. Parts  1112  and  1114  are then depicted in  FIG. 16  at time T 14 , following completion of the packaging operation(s) via packaging module  1604 . Reel  910  can be then be utilized (i.e., if required) to implement a reeling operation. The process can then continue, as indicated at continuation block  1608 .  
         [0068]      FIG. 17  illustrates a block diagram illustrative of a system  1700  that includes a final testing operation in association with a reel-to-reel mechanism, in accordance with an alternative embodiment of the present invention. Parts  1112  and  1114  are depicted in  FIG. 17  at time T 15 , following a reeling operation (i.e., if required) implemented via reel  910 . Parts  1112  and  1114  can be subject to one or more testing operations implemented by a testing module  1704 . All final testing much be accomplished prior to shipment of the final product. The testing phase accomplished via testing module  1704  can be implemented following singulation. Parts  1112  and  1114  are thereafter depicted in  FIG. 17  at time T 16 , prior to implementation of a reeling operation (i.e., if required) via reel  910 . The process then continues to the process depicted in  FIG. 18 , as indicated at continuation block  1708 .  
         [0069]      FIG. 18  illustrates a block diagram illustrative of a system  1800  that includes packing and shipping operations, in accordance with an alternative embodiment of the present invention. In  FIG. 18 , an optional “OR” block  1801  is depicted to indicate that the process can continue to a singulation operation via a singulation module  1802  or directly toward packaging via a packaging module  1804  and a packaging module  1806 . Note that in FIGS.  9  to  18 , systems  900 - 1800  illustrated therein can constitute an overall system in which parts are reeled/un-reeled, coiled/uncoiled, spooled/unspoiled in and out of various processes implemented respectively via various modules. The desire of the embodiment of FIGS.  9  to  18  is to accomplish an entire manufacturing process with the fewest reel-handling operations as possible. The reels depicted in FIGS.  9  to  18  can be implemented as multiple reels, a single reel, or only two reels, depending upon design constraints and goals. In the alternative embodiment of FIGS.  9  to  18 , a dual-plastic process has been substituted for the camera masking operations depicted in the preferred embodiment of FIGS.  1  to  9 .  
         [0070]     The embodiments and examples set forth herein are presented to best explain the present invention and its practical application and to thereby enable those skilled in the art to make and utilize the invention. Those skilled in the art, however, will recognize that the foregoing description and examples have been presented for the purpose of illustration and example only. Other variations and modifications of the present invention will be apparent to those of skill in the art, and it is the intent of the appended claims that such variations and modifications be covered. For example, as utilized herein, the terms sensor, sensing element, IC (integrated circuit), and die can be utilized to refer to silicon circuitry that permits measurement. It is understood that sensing elements other than silicon can also be implemented in accordance with the embodiments disclosed herein.  
         [0071]     The description as set forth is not intended to be exhaustive or to limit the scope of the invention. Many modifications and variations are possible in light of the above teaching without departing from the scope of the following claims. It is contemplated that the use of the present invention can involve components having different characteristics. It is intended that the scope of the present invention be defined by the claims appended hereto, giving full cognizance to equivalents in all respects.

Technology Category: 5