Abstract:
The invention provides an embossed carrier tape molding and sealing apparatus which is devised so that the molding of the embossed carrier tape and the sealing of electronic parts can be efficiently performed. An embossed carrier tape molding and sealing apparatus is constructed by installing, on a continuous conveying path for a thermoplastic resin tape  10,  [i] a molding part heating means  110  which heats and softens the molding parts, [ii] a molding means  130  which positions the above-mentioned heated parts in a mold  132,  and subjects these parts to embossing-molding, [iii] a hole working means  150  which forms guide holes at specified intervals in the side portions of the above-mentioned thermoplastic resin tape  10,  [iv] a product insertion stage  210  which places products  20  in the recesses  12  formed by the aforementioned embossing-molding, [v] a covering tape supply means  230  which supplies a covering tape  30  to the upper surface of the recesses  12  formed by the above-mentioned embossing-molding of the above-mentioned thermoplastic resin tape  10,  and [vi] a tape thermal-bonding means  250  which thermally bonds the above-mentioned covering tape  30  to the above-mentioned thermoplastic resin tape  10  at the peripheral edges of the above-mentioned recesses  12.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The invention relates to a molding and sealing apparatus which forms an embossed carrier tape, places and seals electronic parts, such as connectors, therein and places the tape on a reel to supply the electronic parts to automated assembly machines, etc.  
         DESCRIPTION OF THE PRIOR ART  
         [0002]    Embossed carrier tapes have periodically spaced recesses that accommodate electronic parts, such as connectors, at specified intervals along the direction of length of a tape. The tapes also have guide holes formed in the edge portion of the tape on one or both sides used to convey the tape as needed. In the case of such embossed carrier tapes, electronic parts are placed in a sealed state by inserting the electronic parts into the above-mentioned recesses, covering the top ends of the recesses with a covering tape and heat-sealing the covering tape. The tape in which such electronic parts have thus been sealed is taken up on a reel, and used to supply the electronic parts to an automated assembly machine, etc.  
           [0003]    Conventionally, in the molding of such embossed carrier tapes and the sealing of the electronic parts, a molding apparatus which manufactures the embossed carrier tape by the embossing-molding of a thermoplastic resin tape, and a separate thermal bonding apparatus which inserts electronic parts into the manufactured embossed carrier tape and thermally bonds a covering tape, are respectively used. These respective operations are performed separately.  
           [0004]    However, in the art described above, after the embossed carrier tape has been molded, it is necessary to take the tape up on a reel, transport the reel to another location, dereel the tape, insert electronic parts into the embossed carrier tape, thermally bond the covering tape, and then again take the embossed carrier tape up on a reel. Accordingly, a considerable amount of machinery installation space, operating space and labour is required. Accordingly, it would be beneficial to provide an embossed carrier tape molding and sealing apparatus in which the molding of the embossed carrier tape and the sealing of electronic parts can be efficiently performed.  
         SUMMARY OF THE INVENTION  
         [0005]    In order to achieve the above-mentioned object, the present invention provides an embossed carrier tape molding and sealing apparatus which has, on a continuous conveying path for a thermoplastic resin tape, [i] a molding part heating means which heats and softens the molding parts, [ii] a molding means which positions the above-mentioned heated parts in a mold and subjects these parts to embossing-molding, [iii] a hole working means which forms guide holes at specified intervals in the side portions of the above-mentioned thermoplastic resin tape, [iv] a product insertion stage which places products in the recesses formed by the aforementioned embossing-molding, [v] a covering tape supply means which supplies a covering tape to the upper surface of the recesses formed by the above-mentioned embossing-molding of the above-mentioned thermoplastic resin tape, and [vi] a tape thermal-bonding means which thermally bonds the above-mentioned covering tape to the above-mentioned thermoplastic resin tape at the peripheral edges of the above-mentioned recesses.  
           [0006]    In the present invention, when the thermoplastic resin tape is moved along the continuous conveying path, the molding parts are first heated and softened by the molding part heating means. Next, the heated and softened parts are pressed into the mold by the molding means, so that embossing-molding is performed. Furthermore, guide holes are formed by the hole working means at specified intervals in the side parts of the thermoplastic resin tape. Next, products are inserted into the embossing-molded recesses by the product insertion stage and a covering tape is supplied to the upper surfaces of the recesses by the covering tape supply means. The covering tape is thermally bonded to the thermoplastic resin tape by the tape thermal-bonding means, so that the products inserted into the recesses are sealed inside the recesses. The embossed carrier tape containing products thus obtained can then be appropriately taken up on a reel., etc.  
           [0007]    In one embodiment of the present invention, the above-mentioned molding means is constructed from [a] a mold which has [i] an outer frame block that has a receiving part that is C-shaped, [ii] an inner frame block that is assembled with the outer frame block, and [iii] an insert which is sandwiched between the outer frame block and inner frame block, and [b] a pressurized gas delivery means which presses the above-mentioned heated and softened portions of the above-mentioned thermoplastic resin tape into the above-mentioned mold. As the mold is constructed from an outer frame block, an inner frame block and an insert, working or forming the material is easily accomplished even in the case of complicated shapes. Furthermore, various shapes can be handled merely by replacing parts.  
           [0008]    In another embodiment of the present invention, the conveying path is equipped with guide rails which are disposed on both sides so that guide grooves that match the width of the above-mentioned thermoplastic resin tape are formed. Rotating teeth which engage with the guide holes formed by the hole working means, and the spacing of the guide rails is made variable. This allows thermoplastic resin tapes of various widths to be accommodated merely by altering the spacing of the guide rails and rotating teeth.  
           [0009]    In another embodiment of the present invention, the hole working means has a plurality of punches that are lined up at specified intervals along the sides of the above-mentioned thermoplastic resin tape, and pilot pins which are inserted into already-formed guide holes whereby the pilot pins position the above-mentioned thermoplastic resin tape when hole working is performed by the above-mentioned punches. A tension roller is provided which is pressed against the rotating teeth and which clamps the thermoplastic resin tape between the roller and the rotating teeth. A means is also provided which releases the pressing contact of the tension roller during the hole working performed by the punches and pilot pins. The pressing contact of the aforementioned tension roller can be released during hole working by means of the punches and pilot pins. In this state, the pilot pins can be inserted into guide holes that have already been formed, so that the thermoplastic resin tape is positioned and holes can be formed by means of the punches. Specifically, as a result of the release of the pressing contact of the above-mentioned tension roller, movement of the thermoplastic resin tape becomes possible. Positional deviation can be corrected by inserting the pilot pins into guide holes that have already been formed, so that the formation of holes by means of the punches can be performed in accurate positions.  
           [0010]    In the present invention, the embossing-molding of the thermoplastic resin tape and the sealing of products such as electronic parts, etc., can be performed continuously, while the thermoplastic resin tape is caused to move along a continuous conveying path. As a result, the installation space and working space required for the apparatus can be reduced, the working efficiency can be increased, and power can be saved. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a schematic structural diagram which illustrates a first embodiment of the embossed carrier tape molding and sealing apparatus of the present invention.  
         [0012]    [0012]FIG. 2 is an overall front view of the same apparatus.  
         [0013]    [0013]FIG. 3 is a partial enlarged front view which shows the molding apparatus of the same apparatus.  
         [0014]    [0014]FIG. 4 is a left-side view of the same molding apparatus.  
         [0015]    [0015]FIG. 5 shows partial enlarged sectional views which illustrate the molding part heating means and molding means of the same molding apparatus.  
         [0016]    [0016]FIG. 6 is an exploded perspective view which shows one example of the mold used in the same molding apparatus.  
         [0017]    [0017]FIG. 7 is an exploded perspective view which shows another example of the mold used in the same molding apparatus.  
         [0018]    [0018]FIG. 8 is a sectional view which illustrates the operation of the hole working means in the same molding apparatus.  
         [0019]    [0019]FIG. 9 is a sectional view which illustrates the method used to alter the tape guide in the same molding apparatus.  
         [0020]    [0020]FIG. 10 is a process diagram of the embossed carrier tape molding and sealing apparatus of the present invention.  
         [0021]    [0021]FIG. 11 is a partial enlarged explanatory diagram which illustrates the relationship between the pilot pins and the punches in the above-mentioned molding apparatus. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0022]    As is shown in FIGS. 1 and 2, the embossed carrier tape molding and sealing apparatus of the present invention has a continuous conveying path for a thermoplastic resin tape  10  which is pulled out from a first reel  101 . A molding apparatus  100  consisting of a molding part heating means  110 , a molding means  130  and a hole working means  150 , and a sealing apparatus  200  consisting of a product insertion stage  210 , a covering tape supply means  230  and a tape thermal-bonding means  250 , are positioned along this conveying path.  
         [0023]    Referring to both FIGS. 3 and 4, the molding apparatus  100  has a conveying path  102  for the thermoplastic resin tape  10 . The molding part heating means  110  has heaters  111  and  112  which are disposed above and below the conveying path  102 . The respective heaters  111  and  112  are caused to perform an opening-and-closing action by a first air cylinder  113  and a second air cylinder  114  so that these heaters  111  and  112  clamp the thermoplastic resin tape  10 .  
         [0024]    As is shown in FIGS.  5 ( a ) and  5 ( b ), the heaters  111  and  112  are formed in blocks  115  and  116 , and these respective blocks  115  and  116  contain heat-radiating bodies  117  and  118 . Furthermore, thermoplastic resin tape  10  is clamped by leading edge parts  119  and  120  which have a rectangular shape as seen in a plan view, so that a rectangular region is heated and softened.  
         [0025]    The molding means  130  is constructed from a pressurized gas delivery means  131  which is disposed above, and a mold  132  which is disposed below, so that the conveying path  102  of the thermoplastic resin tape  10  is clamped between these parts. The pressurized gas delivery means  131  consists of a compressed air supply pipe  133  and a pressure-applying nozzle  134  to which this supply pipe  133  is connected. The pressure-applying nozzle  134  has a rectangular opening part  135 . Furthermore, the pressure-applying nozzle  134  is supported via a screw  137  on a bracket  136  that is connected to the frame, so that the height of the pressure-applying nozzle  134  can be adjusted.  
         [0026]    The mold  132  has a mold main body  143  which is held in a block  139  that can be raised and lowered by means of a third air cylinder  138 . Referring also FIG. 6, the mold main body  143  is constructed from an outer frame block  140  which has a receiving part that is C-shaped as seen in a plan view, an inner frame block  141  which is assembled with the outer frame block  140 , and an insert  142  which is clamped between the outer frame block  140  and inner frame block  141 . In this example, a rectangular frame is formed by the outer frame block  140  and the inner frame block  141 . The upper surface of the insert  142  is disposed in the bottom part of the rectangular frame, and a cut-out part  144  is formed in the upper surface of the insert  142 .  
         [0027]    Accordingly, when the rectangular region that has been heated and softened by the molding part heating means  110  is disposed above the mold  132 , the mold  132  is raised by the third air cylinder  138 , so that the mold  132  contacts the undersurface of the thermoplastic resin tape  10 . Meanwhile, the pressure-applying nozzle  134  is disposed on the upper surface of the thermoplastic resin tape  10  facing the mold  132 . In this state, compressed air is fed in from the pressure-applying nozzle  134 , so that the heated and softened rectangular region of the thermoplastic resin tape  10  is pressed into the recess of the mold  132 , thus causing embossing-molding to be performed. The recess  12  thus formed constitutes an accommodating part for electronic parts, etc., (described later). Furthermore, in a case where the mold main body  143  shown in FIG. 6 is used, a small recess  13  which is further recessed in the bottom surface of the recess  12  is formed by the cut-out part  144  formed in the upper surface of the insert  142 .  
         [0028]    Another example of the mold main body is shown in FIG. 7. As in the above-mentioned example, this mold main body  143   a  is constructed from an outer frame block  140   a  which has a receiving part that is C-shaped as seen in a plan view, an inner frame block  141   a  which is assembled with this outer frame block  140   a,  and an insert  142   a  which is clamped between the outer frame block  140   a  and inner frame block  141   a.  A rectangular frame is formed by the outer frame block  140   a  and inner frame block  141   a.  The upper surface of the insert  142   a  is disposed in the bottom part of the rectangular frame, and a projection  145  is formed on the upper surface of the insert  142   a.  In a case where this mold main body  143   a  is used, a small projection  14  is formed on the bottom surface of the recess  12  of the thermoplastic resin tape  10  by the projection  145  of the insert  142   a.    
         [0029]    As is shown in FIG. 8, a plurality of parallel grooves  104  are formed in a table  103  at specified intervals in the direction of width. The pair of guide rails  105  that guide the thermoplastic resin tape  10  are constructed from respective receiving members  106 , pressing members  107  and bolts  108  that connect these members. Furthermore, protruding strips  107   a  that are inserted into the above-mentioned grooves  104  are formed on the lower ends of the pressing members  107 , so that the guide rails  105  are positioned by these protruding strips  107   a.  Guide grooves  109  through which both side edges of the thermoplastic resin tape  10  are passed are formed between the receiving members  106  and the pressing members  107 . The thermoplastic resin tape  10  is conveyed with both side edges being passed through the above-mentioned guide grooves  109 .  
         [0030]    As is shown in FIGS. 2 and 3, the hole working means  150  has a block  152  which is raised and lowered by a fourth air cylinder  151 . A plurality of punches  153  are installed on this block  152  in two rows that are separated by a specified spacing, with these punches  153  extending downward at specified intervals along the conveying direction. The tip ends of the punches  153  are directed so that they overlap the portions of the guide rails  105  in which the above-mentioned guide grooves  109  are formed, and through-holes  154  are formed in these portions.  
         [0031]    When the block  152  is lowered by the fourth air cylinder  151 , as shown in FIGS.  8 ( a ) and  8 ( b ), the punches  153  supported on the block  152  are lowered, and these punches  153  are inserted into the through-holes  154  of the guide rails  105 , so that guide holes  11  with a fixed spacing are formed in both side edges of the thermoplastic resin tape  10  passing through the guide grooves  109  of the guide rails  105 . Furthermore, it would also be possible to form these guide holes  11  in only one side edge of the tape  10 .  
         [0032]    As is shown in FIG. 11, pilot pins  158  are disposed adjacent to the punches  153  that are positioned at the leading end in the direction of advance of the thermoplastic resin tape  10 . The pilot pins  158  protrude further downward than the punches  153 . When the block  152  is lowered, the pilot pins  158  are inserted into guide holes that have already been formed in the thermoplastic resin tape  10  before further holes are opened by the above-mentioned punches  153 , so that the thermoplastic resin tape  10  is positioned. As a result, the spacing of the guide holes  11  can be accurately set.  
         [0033]    As is shown in FIGS.  9 ( a ) and  9 ( b ), changes in the width of the thermoplastic resin tape  10  can be handled merely by altering the spacing of the guide rails  105 . Specifically, the spacing of the pair of guide rails  105  can be altered by changing the grooves  104  into which the projecting strips  107  on the lower ends of the pressing members  107  are inserted. As a result, the spacing of the guide grooves  109  can be altered to match the width of the thermoplastic resin tape  10 . In this case, the spacing of the punches  153  of the hole working means  150  is also altered to match the through-holes  154  of the guide rails  105 .  
         [0034]    Referring again to FIGS. 1 and 2, the product insertion stage  210  is located in a position that allows electronic parts  20  such as connectors, etc., to be manually inserted into the recesses  12  of the thermoplastic resin tape  10  one at a time. However, the insertion of these electronic parts  20  could also be accomplished by means of a universally known automated supply device.  
         [0035]    The covering tape supply means  230  is constructed from a second reel  231  on which a covering tape  30  is wound, and a roller  231  which causes the covering tape  30  pulled out from this second reel  231  to cover the upper surface of the thermoplastic resin tape  10 , so that the electronic parts  20  inserted into the recesses  12  are sealed inside these recesses  12 .  
         [0036]    A tape thermal-bonding means  250 , which has a pair of heaters  251  (on the left and right) that are raised and lowered by a driving mechanism not shown in the figures, is disposed beyond the above-mentioned covering tape supply means  230 . Receiving pads  252  (see FIG. 2) are disposed beneath the heater  251  on both sides of the conveying path. Both side edges of the thermoplastic resin tape  10  and covering tape  30  are clamped between the heaters  251  and receiving pads  252 , so that these tapes are thermally bonded.  
         [0037]    As is shown in FIGS. 1 and 2, a pair of wheels with rotating teeth  155  that engage with the guide holes  11  are disposed beneath the conveying path beyond the tape thermal-bonding means  250 . A tension roller  156  that is pressed against the rotating teeth  155  is disposed above the conveying path. The tension roller  156  is pivot-supported on the tip end of an arm  159  that is supported by a supporting shaft  157 . The tension roller  156  is constantly pressed against the rotating teeth  155  by a spring (not shown in the figures) that drives the arm  159  downward.  
         [0038]    Accordingly, the embossed carrier tape  40  containing electronic parts sealed therein, is intermittently fed out at a specified speed as a result of the pair of wheels with rotating teeth  155  that engage with the guide holes  11 .  
         [0039]    An air cylinder  160  is disposed beneath the arm  159 , and is positioned so that the operating rod  161  of this air cylinder  160  contacts the arm  159 . When the block  152  of the hole working means  150  is lowered, the air cylinder  160  is actuated so that the rod  161  is extended, thus pushing the arm  159  upward so that the tension roller  156  is removed from the rotating teeth  155 . As a result, the embossed carrier tape  40  is allowed to move slightly in the forward-rearward direction within the range of the spacing of the rotating teeth  155  and the guide holes  11 , so that positional correction by the pilot pins  158  is not hindered. In cases where the width of the thermoplastic resin tape  10  is changed, it is also necessary to change the spacing of the rotating teeth  155  so that the teeth will engage with the guide holes  11  of the thermoplastic resin tape  10 .  
         [0040]    A third reel  270  on which the embossed carrier tape  40  that has been sealed by the covering tape  30  is taken up is disposed beyond the rotating teeth  155  and tension roller  156 . This third reel  270  is caused to rotate in accordance with the conveying speed of the embossed carrier tape  40  by a driving mechanism not shown in the figures.  
         [0041]    Tapes consisting of thermoplastic resin tape materials such as polystyrenes, polyesters, polyvinyl chlorides or acrylonitrile, etc., are used as the thermoplastic resin tape  10  and covering tape  30 . Moreover, resin tapes containing carbon may be used as an anti-static measure.  
         [0042]    Next, the operation of this embossed carrier tape molding and sealing apparatus will be described with reference also being made to the flow chart for the same apparatus shown in FIG. 10. First, the thermoplastic resin tape  10  is pulled out from the first reel  101 , and is passed through the guide grooves  109  of the guide rails  105 . Guide holes  11  are formed beforehand in a portion of the tape  10  with a specified length located at the tip end of the tape  10  by operating the guide hole working means  150 , and the rotating teeth  155  are engaged with these guide holes  11  formed in the tip end portions. When the apparatus is operated in this state, the rotating teeth  155  rotate intermittently, so that the tape  10  is conveyed. Then, the tape  10  is first clamped between the upper and lower heaters  111  and  112  of the molding part heating means  110 , so that a rectangular region that is to be subjected to embossing is heated and softened.  
         [0043]    Next, when the above-mentioned heated and softened region moves into the molding means  130 , the mold  132  rises and contacts the undersurface of the tape, and compressed air is fed in the direction of the mold  132  from the pressure-applying nozzle  134  of the pressurized gas delivery means  131 . As a result, the heated and softened region of the tape  10  is pushed into the interior of the mold  132 , so that a recess  12  is formed.  
         [0044]    The tape  10  thus subjected to embossing-molding is then fed into the guide hole working means  150 . The punches  153  are lowered as a unit with the block  152  by the fourth air cylinder  151 , and these punches  153  are inserted into the through-holes  154  of the guide rails  105 , so that guide holes  11  with a fixed spacing are formed in both side edges of the thermoplastic resin tape  10  passing through the guide grooves  109 . Prior to this hole opening work, the pilot pins  158  are inserted into guide holes  11  that have already been formed, so that the thermoplastic resin tape  10  is positioned. These guide holes  11  engage with the rotating teeth  155  that are disposed beyond the tape thermal-bonding means  250 , and provide a driving force that pulls out the tape  10 .  
         [0045]    The tape  10  that has thus been embossing-molded is fed “as is” into the sealing apparatus  200 . In the sealing apparatus  200 , electronic parts  20  are first inserted one at a time into the recesses  12  in the product insertion stage  210 . Next, the above-mentioned recesses  12  are covered from above with the covering tape  30  by the covering tape supply device  230 . As a result, the electronic parts  20  are disposed inside the recesses  12 , and the upper surfaces of these electronic parts are covered by the covering tape  30 .  
         [0046]    Then, in the tape thermal-bonding means  250 , the heaters  251  are pressed against both side edges of the thermoplastic resin tape  10  and covering tape  30 , so that both side edges of the thermoplastic resin tape  10  and covering tape  30  are thermally bonded to each other. As a result, the electronic parts  20  are disposed inside the recesses  12  of the tape  10 , and sealed by the covering tape  30 . The embossed carrier tape  40  containing electronic parts  20  that has thus been manufactured is taken up on the third reel  270 .  
         [0047]    Accordingly, in the present apparatus, the molding of the thermoplastic resin tape  10  and the sealing of the electronic parts  20  can be performed continuously, so that the working efficiency is extremely good. Furthermore, compared to a case in which the above-mentioned operations are performed separately, the overall apparatus is compact, so that the amount of installation space and working space required for the apparatus can be reduced.