Carrier Tape, The Process, Use of Surface Mount Technology (SMT), and Tek Pak's Innovative Beginnings

Surface Mount Technology (SMT) revolutionized the electronics manufacturing business. Instead of inserting the leads of electronic components through holes in the circuit board (through-hole technology), SMT places the electronic components directly onto the surface of the circuit board. This new technique dramatically increased the speed and accuracy through which electronic components could be placed and soldered onto circuit boards. Lightning-fast "chip shooters" can place the components (as small as 0.008 inches x 0.016 inches) onto circuit boards at rates of up 60,000 chips per hour. These high-speed processes take place every day around the world. But how are the components presented to the high-speed pick-up nozzles with the required precision? And how are the chips kept completely clean of dust or microscopic debris during the manufacturing process?

Electronic components are placed in the pockets of long, narrow strips of thin plastic (or paper) called Carrier Tape. The components are then sealed into the tape pockets with a Cover Tape and then rolled up into reels for transport to circuit board manufacturers. That's where Tek Pak comes in: exceeding client expectations and setting the standard for excellence in the global Carrier Tape community. Tony Beyer, Tek Pak's founder, and owner, was involved in the initial development of Carrier Tape in the late 1980s. Mr. Beyer leveraged this knowledge with his thermoforming and tooling experience to create Tek Pak in 1992, integrating Mr. Beyer's innovative approach to designing and producing carrier tapes. Tek Pak has been making Carrier Tapes for all shapes of sizes of electronic components ever since, for over 30 years.  

Do You Support Diversity?

Are you interested in becoming part of the Diversity 2025 vendor project for Tek Pak? Diversity is felt to include all similarities and differences we each possess based on, but not limited to, the characteristics we were born with, experiences had, and choices made. Tek Pak embraces a working relationship with a multiplicity of vendors and suppliers.

Most Carrier Tapes are manufactured from thermoplastics (mainly polystyrene and polycarbonate). Small passive components (resistors, capacitors, etc.) are packaged in paper Carrier Tapes, but Tek Pak does not produce those. Tek Pak primarily produces polystyrene Carrier Tapes with permanent static-dissipative properties to protect the components and SMT equipment from static discharge damage.

The basic format of Carrier Tape has been standardized to ensure that any circuit board assembly company worldwide can handle the variety of components packaged therein. Tek Pak has been a leader in the standardization of Carrier Tapes, having served on the Automated Component Handling (ACH) committee of the Electronic Components Industry Association (ECIA) for over 25 years. The primary standard for Carrier Tapes is EIA-481 and can be purchased through IHS. The widths of Carrier Tape described in this standard range from 4 mm to 200 mm. The most used are 8 mm, 12 mm, 16 mm, 24 mm, 32 mm, 44 mm, and 56 mm. Tapes up to 24 mm in width have sprocket holes along one edge of the tape. Tapes 32 mm and wider have sprocket holes along both edges of the tapes. In all cases, the sprocket-hole pitch is 4 mm. Tek Pak is happy to assist with any questions regarding this standard. 

Along the way, Tek Pak revolutionized new Carrier Tape development by offering 3-day prototyping. Prior to that, the standard lead time was measured in weeks, not days. This short lead time expanded the market for Carrier Tape, making it possible for prototype components to be packaged and tested for automation in Carrier Tape. We now offer 12-hour prototyping for the most urgent development needs. 

Tek Pak was issued a patent for its Nitro™ Carrier Tape, which has strong pockets and sharply-defined features inside the pockets. This development has made it possible to package odd-form components into Carrier Tape and facilitate the automatic assembly of difficult-to-handle parts. Carrier Tape has expanded beyond strictly electronics and has found applications in the medical, bio-medical, and pharmaceutical industries. Carrier Tape remains the most efficient means to handle large volumes of components automatically, and Tek Pak is constantly looking for new applications for Carrier Tape. 

https://blogs.babson.edu/undergraduate/2018/08/17/what-is-a-carrier-tape/