Manufacturing method of cleaning brush for molding type and manufacturing method of resin molding apparatus

Abstract

To provide a method for manufacturing a mold cleaning brush in which a bristle material having high density can be formed around a shaft member.SOLUTION: A method for manufacturing a mold cleaning brush 30 for cleaning a mold provided in a resin molding device includes the steps of: preparing a channel brush formed by fixing a bristle material 33 to a channel member 35; spirally wrapping and fixing the channel brush 36 around a shaft member 38; and cutting a tip of the bristle material 33. By cutting the tip of the bristle material 33, a short bristle region 31R that includes the bristle material 33 having a first length and a long bristle region 32R that includes the bristle material 33 having a second length longer than the first length are formed at the channel brush 36 on the shaft member 38.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] This specification relates to a method for manufacturing a cleaning brush for a mold and a method for manufacturing a resin molding apparatus.

Background Art

[0002] In a resin molding apparatus, a substrate to which electronic components such as ICs (Integrated Circuits), transistors, and capacitors are connected is prepared as an object to be molded. By performing resin molding using methods such as the transfer molding method, the compression molding method (compression mold method), and the injection molding method (injection mold method), the electronic components on the substrate are resin-sealed.

[0003] Resin (also referred to as resin pieces or resin scraps) and the like generated during the implementation of resin molding may remain on the mold of the resin molding apparatus. As disclosed in Japanese Utility Model Laid-Open No. 02-137217 (Patent Document 1), the mold is cleaned using a cleaning brush for the mold.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the cleaning brush for a mold disclosed in Japanese Utility Model Laid-Open No. 02-137217 (Patent Document 1), the tip shape of the bristle portion of the brush is determined to match the shape of the mold. Patent Document 1 states that according to such a brush, the bristle portion can reach the surface portion of the molding surface and clean the surface portion, and the bristle portion can also reach the bottom of the cavity and clean the bottom.

[0006] In the method for manufacturing a brush as described above, a plurality of tufts of hair material are fixed to the outer periphery of the shaft member, whereby a plurality of tufted portions are formed on the outer periphery of the shaft member. A space is required around the portion where the tufts of hair material are tufted in order to perform the operation of fixing the tufts of hair material to the shaft member. Since it is necessary to secure a space, it is difficult to reduce the interval between adjacent tufts of hair material, and it is difficult to form hair material having a high density on the peripheral surface of the shaft member.

[0007] This specification aims to disclose a method for manufacturing a cleaning brush for a mold and a method for manufacturing a resin molding apparatus, which can form hair material having a higher density around a shaft member compared to the prior art.

Means for Solving the Problems

[0008] In one aspect of the present disclosure, a method for manufacturing a cleaning brush for a mold for cleaning a mold provided in a resin molding apparatus includes a step of preparing a channel brush formed by fixing hair material to a channel member, a step of spirally winding and fixing the channel brush around a shaft member extending in the axial direction, and a step of cutting the tips of some or all of the hair material in a state where the channel brush is wound around the shaft member. By cutting the tips of some or all of the hair material, a short hair region including the hair material having a first length and a long hair region including the hair material having a second length longer than the first length are formed on the channel brush on the shaft member.

[0009] In another aspect of the present disclosure, a method for manufacturing a resin molding apparatus is a method for manufacturing a resin molding apparatus including a mold, and includes a step of producing a cleaning brush for a mold by the method for manufacturing a cleaning brush for a mold in one aspect of the present disclosure. The short hair region of the cleaning brush for a mold is arranged so as to be able to contact a convex portion of the mold, and the long hair region of the cleaning brush for a mold is arranged so as to contact a concave portion of the mold.

Advantages of the Invention

[0010] According to the method for manufacturing a cleaning brush for a mold having the above configuration and the method for manufacturing a resin molding apparatus, it is possible to configure a hair material having a higher density around the shaft member as compared with the prior art.

Brief Description of the Drawings

[0011]

Figure 1

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Embodiments for Carrying Out the Invention

[0012] Embodiments of the present disclosure will be described below. In the embodiments described below, when referring to the number, amount, etc., unless otherwise specified, the scope of the present disclosure is not necessarily limited to such number, amount, etc. Each component is not necessarily essential for the present disclosure, unless otherwise specified. The same parts and corresponding parts are given the same reference numerals, and duplicate descriptions may not be repeated.

[0013] (Resin Molding Apparatus 100) FIG. 1 shows a functional block diagram of an example of a resin molding apparatus 100 in an embodiment. The resin molding apparatus 100 includes a control unit 2, a supply module 1, a resin molding module 4, and a molded product carrying-out module 5. The control unit 2 is configured to be able to control the supply module 1, the resin molding module 4, and the molded product carrying-out module 5.

[0014] The supply module 1 is configured to be able to supply a molding object before molding and a resin material to the resin molding module 4. The resin molding module 4 is configured to be able to manufacture a resin molded product by clamping a mold and resin-molding the molding object. The molded product carrying-out module 5 is configured to be able to carry out the resin molded product after removing unnecessary resin portions of the molding object after molding. The supply module 1, the resin molding module 4, and the molded product carrying-out module 5 are detachable from each other and interchangeable. Also, the number of resin molding modules 4 can be increased or decreased.

[0015] FIG. 2 is a plan view schematically showing a main part structure inside the resin molding apparatus 100. FIG. 3 is a cross-sectional view of the main part taken along the line III-III shown in FIG. 2. As mainly shown in FIG. 2, the resin molding apparatus 100 includes a supply unit 10, a mold cleaning brush 30, a molding unit 40, a carrying-out mechanism 50, and a discharge unit 60.

[0016] Referring to FIGS. 1 to 3, the supply module 1 mainly includes a supply unit 10. An object to be molded before molding is placed in the supply unit 10. The object to be molded is generally a substrate to which an electronic element such as a semiconductor chip is connected. As the substrate, for example, a lead frame, a printed wiring board, a metal substrate, a resin substrate, a semiconductor substrate, and a ceramic substrate are used.

[0017] The resin molding apparatus 100 further includes a transport mechanism (not shown), and this transport mechanism is configured to be movable between the supply module 1 and the resin molding module 4. The retracted position of the transport mechanism is in the supply module 1. By the transport mechanism, the substrate is carried into the molding unit 40 from the supply unit 10 together with the resin material. As the resin material, for example, a tablet-shaped resin formed by compacting a powdery thermosetting resin is used.

[0018] The resin molding module 4 mainly includes a molding unit 40. The molding unit 40 includes a lower mold 41 and an upper mold 42 (FIG. 3) as molding dies, and a clamping mechanism (not shown) for clamping the molding dies. In the molding unit 40, the object to be molded is resin-molded by clamping the lower mold 41 and the upper mold 42 by the clamping mechanism.

[0019] The molded product unloading module 5 mainly includes a discharge unit 60. The molded object after molding is unloaded from the molding unit 40 to the discharge unit 60 by the unloading mechanism 50, gate processing is performed in the discharge unit 60, and it is finally stored in the out magazine unit.

[0020] The unloading mechanism 50 is configured to be movable between the resin molding module 4 and the molded product unloading module 5. The unloading mechanism 50 has a cleaning brush 30 for the molding die. Here, the unloading mechanism 50 includes a first main body 51 and a second main body 52. The molded object after molding is discharged by the movement of the first main body 51 in the direction of arrow A1 and the movement of the second main body 52 in the direction of arrow A2. When the second main body 52 moves in the direction of arrow A2, the molding die is cleaned.

[0021] Here, a cleaning brush 30 for the mold is provided at a portion of the second main body 52 of the carry-out mechanism 50 close to the molding portion 40. Using the lower mold 41 and the upper mold 42 as molds, a resin molding of an object to be molded is performed, and cleaning is performed by removing the resin from the mold using the cleaning brush 30 for the mold.

[0022] In order to clean the mold of the resin molding apparatus 100, one or more cleaning brushes 30 for the mold (described in detail below) are provided in the carry-out mechanism 50 of the resin molding apparatus 100. When two are provided as shown in FIG. 3, one cleaning brush 30 for the mold removes the resin from the lower mold 41, and the other cleaning brush 30 for the mold removes the resin from the upper mold 42 (FIG. 3), and thus the mold in the molding portion 40 is cleaned.

[0023] (Cleaning Brush 30 for Mold and Method for Manufacturing the Same) FIG. 4 is a diagram schematically showing the external structure of the cleaning brush 30 for the mold. FIG. 5 is a cross-sectional view showing a state where the long hair region 32R of the cleaning brush 30 for the mold is in contact with the bottom surface 41b of the cavity (recess) of the lower mold 41. FIG. 6 is a cross-sectional view showing a state where the short hair region 31R and the long hair region 32R of the cleaning brush 30 for the mold are in contact with the surface of the lower mold 41 (the surface 41a and the bottom surface 41b of the recess).

[0024] As shown in FIGS. 3 to 6, the cleaning brush 30 for the mold has a form of a so-called roll brush. The cleaning brush 30 for the mold includes a shaft member 38 that rotates about an axis 38c (FIG. 3), a channel member 35 fixed to the shaft member 38 (also refer to FIGS. 3 and 7), and a hair material 33 fixed to the channel member 35. The shaft member 38 has a columnar shape extending along the axis 38c from one end to the other end.

[0025] As a manufacturing method of the cleaning brush 30 for a molding die, a channel brush 36 (FIG. 7) is formed by fixing the hair material 33 to the channel member 35 (FIG. 7). After preparing such a channel brush 36, the channel brush 36 is spirally wound around and fixed to the periphery of the shaft member 38 (FIGS. 3, 4, 8) (see FIG. 8). At this time, the end portion 35T (FIG. 8) in the longitudinal direction of the channel member 35 may be fixed to the surface of the shaft member 38 by welding or the like. Thereafter, with the channel brush 36 wound around the shaft member 38, the tips of some or all of the hair materials 33 are cut with a grinder or the like (see FIG. 9).

[0026] As a result, in the channel brush 36 on the shaft member 38, a short hair region 31R including the hair material 33 (31) having the first length L1 (FIG. 5) and a long hair region 32R including the hair material 33 (32) having the second length L2 (FIG. 5) longer than the first length L1 are formed.

[0027] As shown in FIGS. 3, 5, and 6, in the cleaning brush 30 for a molding die of the present embodiment, a plurality of short hair regions 31R and a plurality of long hair regions 32R are alternately arranged in the circumferential direction centered on the shaft member 38. Here, two short hair regions 31R and two long hair regions 32R are alternately provided around the shaft member 38. As shown in FIG. 4, in the cleaning brush 30 for a molding die, when looking at the cross-sectional shape at a specific position, a plurality of short hair regions 31R and a plurality of long hair regions 32R are alternately arranged in the axial direction (see also FIG. 9).

[0028] The hair material 33 (31) included in the short hair region 31R extends so as to protrude radially outward from the channel member 35 along the radial direction of the shaft member 38 from its root side toward its tip side. The hair material 33 (32) included in the long hair region 32R also extends so as to protrude radially outward from the channel member 35 along the radial direction of the shaft member 38 from its root side toward its tip side.

[0029] The angular range in the circumferential direction centered on the shaft member 38 provided with the short hair region 31R can be set, for example, to 60° or more and 90° or less, and the angular range in the circumferential direction centered on the shaft member 38 provided with the long hair region 32R can also be set, for example, to 60° or more and 90° or less.

[0030] Regarding the short hair region 31R, the angular range in the circumferential direction referred to here means identifying the root portion of the hair material 33(31) located on the most forward side in the rotational direction in the short hair region 31R and the root portion of the hair material 33(31) located on the most rearward side in the rotational direction in the short hair region 31R, and in a two-dimensional plane perpendicular to the axis 38c and including these two root portions, it is the angle formed by these two root portions and the axis 38c.

[0031] Regarding the long hair region 32R, the angular range in the circumferential direction referred to here means identifying the root portion of the hair material 33(32) located on the most forward side in the rotational direction in the long hair region 32R and the root portion of the hair material 33(32) located on the most rearward side in the rotational direction in the long hair region 32R, and in a two-dimensional plane perpendicular to the axis 38c and including these two root portions, it is the angle formed by these two root portions and the axis 38c.

[0032] For example, three short hair regions 31R provided in an angular range of 60° and three long hair regions 32R provided in an angular range of 60° can be alternately arranged around the shaft member 38. Two short hair regions 31R and two long hair regions 32R may be provided in an angular range of 90° respectively, or they may be provided in different angular ranges such as 50° and 70° and arranged alternately.

[0033] As shown in FIG. 5, the hair material 33(31) constituting the short hair region 31R has a length L1 from the channel member 35 and extends along the radial direction of the shaft member 38. The hair material 33(32) constituting the long hair region 32R has a length L2 from the channel member 35 and extends along the radial direction of the shaft member 38.

[0034] The distance from the axis 38c of the shaft member 38 to the tip of the blank 33 (32) is, for example, 20 mm to 30 mm. In the present embodiment, the length L2 of the blank 33 (32) constituting the long hair region 32R is longer than the length L1 of the blank 33 (31) constituting the short hair region 31R.

[0035] The difference between the length L2 and the length L1 can be, for example, the same value as the maximum depth of the cavity formed in the lower mold 41, that is, the depth dimension L3 from the surface 41a of the lower mold 41 (the surface 41a of the convex portion in the lower mold 41 where the cavity is not formed) to the bottom surface 41b of the concave portion of the cavity. The difference between the length L2 and the length L1 may be larger than the depth dimension L3. In other words, the relationship (L3 + L1) ≤ L2 may hold. Depending on the specifications, the difference between the length L2 and the length L1 is, for example, 1.0 mm or more, 2.0 mm or less, or 3.0 mm or less. The depth dimension L3 is 1.0 mm or less, or 3.0 mm or less. The lengths L1 and L2 are optimized according to the depth dimension L3.

[0036] As shown in FIGS. 4 to 6, when cleaning the lower mold 41 using the mold cleaning brush 30, the tip of the blank 33 (32) constituting the long hair region 32R contacts the bottom surface 41b of the concave portion of the lower mold 41, and the tip of the blank 33 (31) constituting the short hair region 31R contacts the surface 41a of the convex portion of the lower mold 41. The mold cleaning brush 30 is moved in a direction approaching the lower mold 41.

[0037] As an example, the distance L5 (FIG. 5) from the channel member 35 to the bottom surface 41b of the concave portion of the lower mold 41 can be set to the same value as the length L2 of the blank 33 (32) constituting the long hair region 32R, and the distance L4 from the outer peripheral surface of the shaft member 38 to the surface 41a can be set to the same value as the length L1 of the blank 33 (31) constituting the short hair region 31R.

[0038] In the resin molding apparatus 100 equipped with the cleaning brush 30 for a molding die as described above, when cleaning the molding die using the cleaning brush 30 for a molding die, the hair material 33(32) constituting the long hair region 32R can reach the surface 41a of the convex portion of the lower mold 41 and the side surface which is the inner surface of the cavity and the bottom surface 41b of the concave portion. As the shaft member 38 rotates, the hair material 33(32) can remove resin and the like adhering to the bottom surface 41b of the concave portion. The hair material 33(31) constituting the short hair region 31R can reach the surface 41a of the convex portion of the lower mold 41. As the shaft member 38 rotates, the hair material 33(31) can remove resin and the like adhering to the surface 41a of the convex portion of the lower mold 41.

[0039] (Function and Effect) As described at the beginning, in the conventional method for manufacturing a brush, a plurality of hair material bundles are fixed to the outer periphery of the shaft member, whereby a plurality of hair implanting portions are formed on the outer periphery of the shaft member. A space for performing the operation of fixing the hair material bundle to the shaft member is required around the portion where the hair material bundle is implanted. Since it is necessary to secure a space, it is difficult to reduce the interval between adjacent hair material bundles, and it is difficult to form hair materials having a high density on the peripheral surface of the shaft member. Further, in the conventional method for manufacturing a brush, it is necessary to prepare a plurality of hair material bundles for constituting the hair implanting portion and sequentially fix each of the plurality of hair material bundles to the shaft member. In such a method, a large number of operations of fixing each of the plurality of hair material bundles to the shaft member are required.

[0040] In contrast, according to the manufacturing method of the cleaning brush 30 for the mold of the present embodiment, the channel brush 36 (FIG. 7) is formed by fixing the hair material 33 to the channel member 35 (FIG. 7). After preparing such a channel brush 36, the channel brush 36 is spirally wound around the shaft member 38 (FIGS. 3, 4, 8) and fixed (see FIG. 8). At this time, both ends in the longitudinal direction of the channel member 35 may be fixed to the surface of the shaft member 38 by welding or the like. Thereafter, with the channel brush 36 wound around the shaft member 38, the tips of some or all of the hair materials 33 are cut with a grinder or the like (see FIG. 9).

[0041] According to the above manufacturing method, when the channel brush 36 is spirally wound and fixed, the next part of the channel brush 36 can be wound around the shaft member 38 so as to be adjacent to the part of the channel brush 36 wound one turn (one week before) on the shaft member 38. Compared with the case of implanting the hair material into the shaft member, the hair material 33 can be efficiently arranged on the shaft member 38 at a high density, and thus a higher cleaning effect by the cleaning brush 30 for the mold can be expected.

[0042] (First Modification Example of the Embodiment) FIG. 10 is a plan view showing a state in which the cleaning brush 30 for the mold for the lower mold 41 is cleaning the lower mold 41 in the first modification example of the embodiment. In this lower mold 41, a cavity 46 and a resin passage 45 are formed as recesses 44 inside the parting surface 43 which is a convex portion of the lower mold 41, and the cavity 46 is connected to the cal portion 48 through a plurality of resin passages 45.

[0043] As the cleaning brush 30 for a mold for cleaning such a lower mold 41, for example, corresponding to the shapes of the concave and convex portions in the lower mold 41, a long hair region 32R is provided in a horizontally long shape at the center in the axial direction, and short hair regions 31R are provided on both sides thereof. The long hair region 32R has a width that covers all of the cavity 46 located on the left side of FIG. 10 and all of the cavity 46 located on the right side. The long hair region 32R cleans the cavity 46 and the resin passage 45 as the concave portions of the lower mold 41.

[0044] As the cleaning brush 30 for a mold for cleaning the upper mold corresponding to the above-described lower mold 41, for example, one as shown in FIG. 11 can be used. The cleaning brush 30 for a mold shown in FIG. 11 has a short hair region 31R provided at the center, long hair regions 32R provided on both sides thereof, and short hair regions 31R provided further outside thereof, corresponding to the shapes of the concave and convex portions in the upper mold. The short hair region 31R enables the bottom surface of the concave portion of the cavity of the upper mold to be cleaned.

[0045] The configuration of the lower mold shown in FIG. 10 may be adopted for the upper mold. That is, a resin passage 45 or a cal portion 48 may be provided in the upper mold. Also in that case, the short hair region 31R and the long hair region 32R of the cleaning brush 30 for a mold are appropriately arranged in the same manner as in the case shown in FIG. 10 in accordance with the configuration of the concave and convex portions of the upper mold.

[0046] (Second Modification of the Embodiment) FIG. 12 is a plan view showing another example of the lower mold 41 that can be cleaned by the cleaning brush 30 for a mold in the second modification of the embodiment. In this lower mold 41, a part of the parting surface 43 as a convex portion of the lower mold 41 extends so as to protrude toward the cavity 46 side, and the extended portion constitutes a dam portion 43D. That is, as the convex portion in the lower mold 41, it includes at least one of the parting surface 43 and the surface of the dam portion 43D. For such a lower mold 41 having such a shape, cleaning may be performed using, for example, the cleaning brush 30 for a mold as shown in FIG. 10.

[0047] The configuration of the lower mold shown in FIG. 12 may be adopted for the upper mold. That is, not only the resin passage 45 and the cut portion 48 but also the dam portion 43D may be provided in the upper mold. Also in that case, the short hair region 31R and the long hair region 32R of the mold cleaning brush 30 are appropriately arranged in the same manner as in the case shown in FIG. 10 or the like in accordance with the configuration of the concave and convex portions of the upper mold.

[0048] As described above, the embodiments of the present disclosure have been described. However, the embodiments disclosed this time should be considered as illustrative in all respects and not restrictive. The scope of the present disclosure is indicated by the claims, and it is intended that all modifications within the meaning and scope equivalent to the claims are included.

Explanation of Reference Numerals

[0049] 1 Supply module, 2 Control unit, 4 Resin molding module, 5 Molded product unloading module, 10 Supply unit, 30 Mold cleaning brush, 31R Short hair region, 32R Long hair region, 33 Brush material, 35 Channel member, 35T End portion, 36 Channel brush, 38 Shaft member, 38c Axis, 40 Molding portion, 41 Lower mold, 41a Surface, 41b Bottom surface, 42 Upper mold, 43 Parting surface, 43D Dam portion, 44 Concave portion, 45 Resin passage, 46 Cavity, 48 Cut portion, 50 Unloading mechanism, 51 First main body portion, 52 Second main body portion, 60 Discharge portion, 100 Resin molding apparatus, L1 Length (first length), L2 Length (second length), L3 Dimension, L4, L5 Distance.

Claims

1. A method for manufacturing a cleaning brush for a mold for cleaning a mold provided in a resin molding apparatus, comprising: preparing a channel brush formed by fixing a hair material to a channel member; spirally winding and fixing the channel brush around a shaft member extending in the axial direction; a step of cutting the tips of some or all of the hair materials with the channel brush wound around the shaft member; By cutting the tips of some or all of the hair materials, a short hair region including the hair materials having a first length and a long hair region including the hair materials having a second length longer than the first length are formed on the channel brush on the shaft member; A method for manufacturing a cleaning brush for a mold.

2. The short hair region and the long hair region are alternately arranged side by side in the circumferential direction centered on the shaft member. The method for manufacturing a cleaning brush for a mold according to Claim 1.

3. The angular range in the circumferential direction centered on the shaft member where the short hair region is provided is 60° or more and 90° or less. The angular range in the circumferential direction centered on the shaft member where the long hair region is provided is 60° or more and 90° or less. The method for manufacturing a cleaning brush for a mold according to Claim 1 or 2.

4. The difference between the first length and the second length is 1.0 mm or more. The method for manufacturing a cleaning brush for a mold according to Claim 1 or 2.

5. A method for manufacturing a resin molding apparatus provided with a mold, comprising: a step of manufacturing a cleaning brush for a mold by the method for manufacturing a cleaning brush for a mold according to Claim 1 or 2; the short hair region of the cleaning brush for a mold is arranged so as to be able to contact the convex portion of the mold; the long hair region of the cleaning brush for a mold is arranged so as to contact the concave portion of the mold. A method for manufacturing a resin molding apparatus.

6. The concave portion of the mold includes at least one of the bottom surface of the cavity of the mold and the bottom surface of the resin passage connecting to the cavity. The method for manufacturing a resin molding apparatus according to Claim 5.

7. The convex portion of the mold includes at least one of the parting surface of the mold and the surface of the dam portion provided in the cavity of the mold. The method for manufacturing a resin molding apparatus according to Claim 5.

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