Carrier tapes having tear-initiated cover tapes and methods of making thereof

Abstract

A cover tape for use with a carrier tape, where the cover tape includes at least one tear-initiation feature that defines a predetermined direction of tear to initiate a tear along portions of the cover tape.

1 . A cover tape comprising:
 a film having first and second major surfaces, a lateral portion extending along a longitudinal length of the film, and a medial portion disposed adjacent the lateral portion;   an adhesive portion secured to the first major surface adjacent the lateral portion;   a line of weakness in the first major surface, the line of weakness extending along the longitudinal length of the film adjacent the lateral portion, and configured to enable progressive separation of the medial portion from the lateral bonding portion; and   at least one tear-initiation feature extending through the lateral portion, wherein the tear-initiation feature defines a predetermined direction of tear in the lateral portion to initiate a tear along each of the line of weakness.   
   
   
       2 . The cover tape of  claim 1 , wherein the at least one tear-initiation feature has an arcuate shape. 
   
   
       3 . The cover tape of  claim 1 , wherein the at least one tear-initiation feature is cut through the lateral portion from the second surface of the film. 
   
   
       4 . The cover tape of  claim 3 , wherein the at least one tear-initiation feature is cut prior to securing the adhesive portion to the first major surface. 
   
   
       5 . The cover tape of  claim 1 , wherein the at least one tear-initiation feature is offset from the first and second lines of weakness. 
   
   
       6 . The cover tape of  claim 1 , wherein the film is a multi-layer film. 
   
   
       7 . The cover tape of  claim 6 , wherein the multi-layer film comprises a topcoat layer, a core layer, and a bottom coating. 
   
   
       8 . A method of forming multiple cover tapes, the method comprising:
 forming a film having first and second major surfaces;   cutting a plurality of tracks through the first and second major surfaces of the film;   cutting a plurality of score lines in the first major surface of the film;   coating the first major surface with a plurality of adhesive strips; and   separating the film into sections to form the multiple cover tapes, each cover tape having tear-initiation features defined by the tracks.   
   
   
       9 . The method of  claim 8 , wherein each of the plurality of tracks comprises a row of cut features, wherein each cut feature defines a pair of tear-initiation features. 
   
   
       10 . The method of  claim 8 , wherein the tear-initiation features have arcuate shapes. 
   
   
       11 . The method of  claim 8 , wherein the tracks are cut from the second major surface of the film. 
   
   
       12 . The method of  claim 8 , wherein cutting the plurality of tracks occurs prior to coating the first major surface with the adhesive strips. 
   
   
       13 . The method of  claim 8 , wherein cutting the plurality of tracks occurs after separating the film to form the multiple cover tapes, wherein cutting the plurality of tracks comprises cutting the plurality of tracks while at least one of the cover tapes is wound up as a roll. 
   
   
       14 . A method of using a carrier tape, the method comprising:
 providing the carrier tape having a cover tape bonded to a base portion, wherein the cover tape includes a tear-initiation feature and a score line;   peeling a first portion of the cover tape from the base portion until the peel reaches the tear-initiation feature;   peeling a second portion of the cover tape along the tear-initiation feature;   tearing a third portion of the cover tape in a direction that substantially follows the tear-initiation feature until the tear reaches the score line; and   tearing a fourth portion of the cover tape in a direction that substantially follows the score line.   
   
   
       15 . The method of  claim 14 , wherein the tear-initiation feature has an arcuate shape. 
   
   
       16 . The method of  claim 14 , wherein the cover tape comprises a plurality of tear-initiation features. 
   
   
       17 . The method of  claim 14 , wherein the tear-initiation feature does not intersect the score line. 
   
   
       18 . The method of  claim 14 , wherein at least a portion of the tear-initiation feature has a linear shape. 
   
   
       19 . The method of  claim 14 , wherein the tear-initiation feature is cut prior to applying adhesive materials that bond the cover tape to the base portion.