阅读说明：本技术 树脂成形装置及树脂成形品的制造方法 (Resin molding apparatus and method for manufacturing resin molded product ) 是由 小河冬彦 尾川敬祐 田锹直久 清水久胜 于 2019-06-17 设计创作，主要内容包括：本发明涉及一种树脂成形装置及树脂成形品的制造方法；树脂成形装置包括使第一模与第二模之间的距离变化的合模机构、以及对合模机构进行控制的控制部。控制部执行如下的处理：在将成形对象物配置于成形模的状态下缩小第一模与第二模之间的距离,同时测量由合模机构施加至成形模的压力即合模力；获取所测量的合模力超过预先设定的第一设定值的合模机构的第一位置；将利用修正值修正第一位置而获得的第二位置设定为异物检测位置；以及在成形动作中,基于在异物检测位置所测量的合模力,检测成形模的异物。(The present invention relates to a resin molding apparatus and a method for manufacturing a resin molded product; the resin molding apparatus includes a mold clamping mechanism that changes a distance between a first mold and a second mold, and a control unit that controls the mold clamping mechanism. The control unit executes the following processing: measuring a clamping force, which is a pressure applied to the molding die by a clamping mechanism, while reducing a distance between the first die and the second die in a state where the object to be molded is arranged in the molding die; acquiring a first position of a mold clamping mechanism of which the measured mold clamping force exceeds a preset first set value; setting a second position obtained by correcting the first position with the correction value as a foreign object detection position; and detecting a foreign object in the molding die based on the mold clamping force measured at the foreign object detection position during the molding operation.)

1. A resin molding apparatus for resin-molding a molding object using a molding die including a first die and a second die disposed to face each other, the resin molding apparatus comprising:

a mold clamping mechanism that changes a distance between the first mold and the second mold; and

a control unit for controlling the mold clamping mechanism,

the control unit executes the following processing:

measuring a clamping force, which is a pressure applied to the molding die by the clamping mechanism, while reducing a distance between the first die and the second die in a state where the object to be molded is disposed in the molding die;

acquiring a first position of the mold clamping mechanism at which the measured mold clamping force exceeds a preset first set value;

setting a second position obtained by correcting the first position with the correction value as a foreign object detection position; and

in the molding operation, the foreign matter in the molding die is detected based on the mold clamping force measured at the foreign matter detection position.

2. The resin forming apparatus according to claim 1, wherein the process of detecting the foreign matter includes a process of: in the process of reducing the distance between the first die and the second die to the foreign matter detection position, the presence or absence of foreign matter is determined based on whether or not the clamping force measured in this process exceeds a preset second set value.

3. The resin forming apparatus according to claim 2, wherein the control portion further performs a process of: when the clamping force measured in the process of detecting the foreign object does not exceed the second set value in a state where the distance between the first die and the second die is reduced to the foreign object detection position, a command is given to the clamping mechanism so that the clamping force becomes a preset value.

4. The resin forming apparatus according to claim 2 or 3, wherein the second set value is set to the same value as the first set value.

5. The resin molding apparatus according to claim 2 or 3, wherein the control portion further performs a process of: when the mold clamping force measured in the process of detecting the foreign matter exceeds the second set value, the distance between the first mold and the second mold is enlarged.

6. The resin molding apparatus according to any one of claims 1 to 3, wherein the control section sets the first set value and the correction value in accordance with a property of the molding die.

7. A method for producing a resin molded article, which is a method for producing a resin molded article in which a molding object is resin-molded using a molding die including a first die and a second die disposed in opposition to each other, and which includes the steps of:

measuring a clamping force, which is a pressure applied to the molding die by a clamping mechanism, while reducing a distance between the first die and the second die by the clamping mechanism in a state where the object to be molded is disposed in the molding die;

acquiring a first position of the mold clamping mechanism at which the measured mold clamping force exceeds a preset first set value;

setting a second position obtained by correcting the first position with the correction value as a foreign object detection position; and

in the molding operation, the foreign matter in the molding die is detected based on the mold clamping force measured at the foreign matter detection position.

8. The method of manufacturing a resin molded article according to claim 7, wherein the step of detecting the foreign matter comprises the steps of: in the process of reducing the distance between the first die and the second die to the foreign matter detection position, the presence or absence of foreign matter is determined based on whether or not the clamping force measured in this process exceeds a preset second set value.

9. The method of producing a resin molded article according to claim 8, further comprising the steps of: when the clamping force measured in the process of detecting the foreign object does not exceed the second set value in a state where the distance between the first die and the second die is reduced to the foreign object detection position, a command is given to the clamping mechanism so that the clamping force becomes a preset value.

10. The method of manufacturing a resin molded article according to claim 8 or 9, wherein the second set value is set to the same value as the first set value.

11. The method of producing a resin molded article according to claim 8 or 9, further comprising the steps of: when the mold clamping force measured in the process of detecting the foreign matter exceeds the second set value, the distance between the first mold and the second mold is enlarged.

12. The method of manufacturing a resin molded article according to claim 8 or 9, further comprising a step of setting the first set value and the correction value in accordance with an attribute of the molding die.

Technical Field

The present invention relates to a resin molding apparatus and a method of manufacturing a resin molded product.

Background

In order to protect a semiconductor chip such as an Integrated Circuit (IC) from the environment of light, heat, moisture, or the like, the semiconductor chip is generally sealed with a resin. Such resin sealing is achieved by disposing a support body on which a semiconductor chip is mounted between a molding die including an upper die and a lower die, and filling a cavity including the molding die with a molten resin. Alternatively, a method is known in which a resin material in the form of pellets is supplied to a lower mold in advance and heated, and the both are clamped together.

In order to perform such resin sealing, a support body on which a semiconductor chip is mounted must be disposed between the upper mold and the lower mold, but for some reason, there are cases where an article (hereinafter referred to as "foreign matter") that is not to be a subject of resin sealing is mixed in addition to the support body on which the semiconductor chip that is a subject of resin sealing is mounted. Such foreign matter must be detected before the pressure is applied to the upper and lower dies.

For example, japanese patent application laid-open No. h 06-151489 is directed to "in a semiconductor resin sealing device, when a lead frame is clamped by an upper mold and a lower mold, two pieces of the lead frame may overlap each other, or foreign matter of resin powder may be mixed between the upper mold and the lower mold. In this case, when a clamping pressure at the time of normal resin sealing is applied, the mold may be damaged due to imbalance in the clamping pressure caused by foreign matter. In the conventional method of moving the movable platen up and down only by the toggle mechanism, a considerable mold clamping force is generated at a position where the upper mold and the lower mold are brought into contact, and thus the mold cannot be protected by detecting foreign matters in a low-pressure mold clamping state. "to solve the above problem," a semiconductor resin sealing apparatus capable of detecting whether or not foreign matter is mixed between an upper mold and a lower mold in a low-pressure mold clamping state in a press mechanism that moves a movable platen up and down using a toggle mechanism "is disclosed.

More specifically, in the semiconductor resin sealing device disclosed in the above-mentioned patent document, the presence or absence of a foreign object between the upper mold and the lower mold is determined based on whether or not the current position (mold contact position) obtained by the position detection device is the same as the set position.

Disclosure of Invention

There is no mention of how to set a setting position for determining the presence or absence of a foreign substance in the semiconductor resin sealing device disclosed in the patent document. Therefore, it is difficult to achieve high-accuracy foreign matter detection.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a device and a method capable of accurately detecting a foreign matter which may be mixed between forming dies.

According to one aspect of the present invention, there is provided a resin molding apparatus for resin-molding a molding object using a molding die including a first die and a second die disposed to face each other. The resin molding apparatus includes: a mold clamping mechanism for changing the distance between the first mold and the second mold; and a control unit for controlling the mold mechanism. The control unit executes the following processing: in a state where the object to be molded is disposed in the molding die, a distance between the first die and the second die is reduced, and a clamping force, which is a pressure applied to the molding die by the clamping mechanism, is measured; acquiring a first position of a mold clamping mechanism of which the measured mold clamping force exceeds a preset first set value; setting a second position obtained by correcting the first position with the correction value as a foreign object detection position; and detecting a foreign object in the molding die based on the mold clamping force measured at the foreign object detection position during the molding operation.

According to another aspect of the present invention, there is provided a method of manufacturing a resin molded article, in which a molding object is resin-molded using a molding die including a first die and a second die disposed to face each other. The manufacturing method comprises the following steps: in a state where the object to be molded is disposed in the molding die, a clamping force, which is a pressure applied to the molding die by the clamping mechanism, is measured while the distance between the first die and the second die is reduced by the clamping mechanism; acquiring a first position of a mold clamping mechanism of which the measured mold clamping force exceeds a preset first set value; setting a second position obtained by correcting the first position with the correction value as a foreign object detection position; and detecting a foreign object in the molding die based on the mold clamping force measured at the foreign object detection position during the molding operation.

These and other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description, which is to be read in connection with the accompanying drawings.

Drawings

Fig. 1 is a schematic diagram showing an example of the overall configuration of a resin molding apparatus according to the present embodiment.

Fig. 2 is a schematic diagram showing an example of the configuration (before mold clamping) of a press unit constituting the resin molding apparatus according to the present embodiment.

Fig. 3 is a schematic diagram showing an example of the configuration (mold clamping state) of a press unit constituting the resin molding apparatus according to the present embodiment.

Fig. 4 is a schematic diagram showing an example of a hardware configuration of a control unit constituting the resin molding apparatus according to the present embodiment.

Fig. 5 is a schematic view showing an example of mixing of foreign matter detected in the press unit of the resin molding apparatus according to the present embodiment.

Fig. 6 is a diagram for explaining a process of detecting foreign matter in the press unit of the resin molding apparatus according to the present embodiment.

Fig. 7 is a schematic diagram for explaining a method of setting a foreign matter detection position of the resin molding apparatus according to the present embodiment.

Fig. 8 is a flowchart showing a procedure of setting a foreign matter detection position in the resin molding apparatus according to the present embodiment.

Fig. 9 is a diagram showing an example of setting the foreign matter detection value and the correction value used in the resin molding apparatus according to the present embodiment.

Description of the symbols

1: resin molding apparatus

2: receiving and sending module

3. 3A, 3B, 3C: forming module

4: lead frame supply unit

5: lead frame arrangement unit

6: resin sheet supply unit

7: material carrying-out unit

8: lead frame accommodating unit

10: punching unit

11: lower die

12: loading device

13: unloading device

14: pot for storing food

15: lead frame before sealing

16: resin sheet

17: upper fixing disc

18: upper die

19: movable disc

20: heating device

21: chip and method for manufacturing the same

22: conducting wire

23: mould clamping mechanism

24: plunger piston

25: resin passage

26: hollow cavity

100: control unit

102: input unit

104: output unit

106: main memory

108: optical drive

108A: recording medium

110: processor with a memory having a plurality of memory cells

112: network interface

114: clamping force measuring interface

116: clamping mechanism interface

118: internal bus

120：HDD

122: general purpose OS

124: real-time OS

126: HMI program

128: control program

150: driver

152: strain gauge

200: setting value table

201: forming die type

202: foreign matter detection value

203: correction value

P1: first stage

P2: second stage

S100, S102, S104, S106, S108, S110, S112, S114, S116, S118, S120, S122, S124, S126, S128, S130, S132, S134, S136: procedure (ii)

Detailed Description

Embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same or corresponding portions are denoted by the same reference numerals, and description thereof will not be repeated.

< A. structural example of resin Molding apparatus 1

First, a configuration example of the resin molding apparatus 1 according to the present embodiment will be described. Typically, the resin molding apparatus 1 according to the present embodiment is used as an apparatus for resin-sealing a molding object such as a lead frame on which a chip is placed by molding a resin on a chip placement surface of the molding object. The resin molding apparatus 1 may be configured as a part of an apparatus for manufacturing electronic components. In the following description, a lead frame is given as a typical example of the object to be molded, but the lead frame is not limited thereto, and may be another support such as a substrate.

As chips of electronic parts, for example, Integrated Circuits (ICs), large-scale integrated circuits (LSIs), Light Emitting Diodes (LEDs), Laser Diodes (LDs), semiconductor chips such as photosensors, and electronic device chips such as transistors, resistors, capacitors, and inductors are assumed. Examples of the support include a lead frame made of a metal material, a printed circuit board such as a glass epoxy substrate, a ceramic substrate made of a ceramic material, a metal base substrate made of a metal material, and a flexible substrate made of a resin film such as polyimide.

Fig. 1 is a schematic diagram showing an example of the overall configuration of a resin molding apparatus 1 according to the present embodiment. Referring to fig. 1, a resin molding apparatus 1 includes a receiving and sending module 2 and one or more molding modules 3A, 3B, and 3C (hereinafter, may be collectively referred to as "molding module 3").

The receiving and sending-out module 2 includes a lead frame supply unit 4, a lead frame arranging unit 5, a resin sheet supply unit 6, a material carrying-out unit 7, a lead frame housing unit 8, and a control section 100.

Each forming module 3 comprises a punching unit 10. Each press unit 10 includes a lower die 11 that can be raised and lowered, and an upper die (corresponding to the upper die 18 shown in fig. 2 and 3) that is fixedly disposed above the lower die 11. The upper mold 18 and the lower mold 11 are disposed to face each other to form a molding die. In addition, a plurality of cans 14 are provided in the lower die 11.

The resin molding apparatus 1 further includes a loader 12 and an unloader 13 configured to be movable between the receiving and sending module 2 and each press unit 10.

Here, the operation of the resin molding apparatus 1 will be described. First, the lead frame supply unit 4 sends out the lead frame 15 before sealing, which is an object of resin molding (molding object) received from the outside of the resin molding apparatus 1, to the lead frame alignment unit 5. Then, the lead frame arraying unit 5 aligns the received lead frames 15 before sealing in a predetermined direction, and sends out the aligned lead frames 15 before sealing to the material carrying-out unit 7. At the same time, the resin sheet supply unit 6 sends out the resin sheets 16, which are resin materials received from the outside of the resin molding apparatus 1, to the material carry-out unit 7 by a necessary number (four in fig. 1).

Next, the material unloading unit 7 delivers the aligned predetermined number of (two in fig. 1) lead frames 15 before sealing and the four resin sheets 16 to the loader 12. The loader 12 simultaneously conveys the two pre-sealed lead frames 15 and the four resin sheets 16 received from the material carrying-out unit 7 to the press unit 10. Thereafter, the loader 12 arranges the lead frame 15 before sealing at a predetermined position of the lower mold 11, and supplies the resin sheet 16 to the inside of the can 14 provided in the lower mold 11.

Then, the molding module 3 performs mold clamping, resin molding, and mold opening, whereby the lead frame 15 before sealing is sealed with resin, and a sealed lead frame is produced as a result. Finally, the unloader 13 accommodates the sealed lead frame sealed with resin in the press unit 10 in the lead frame accommodating unit 8.

In the configuration shown in fig. 1, the receiving and sending-out module 2 is formed by integrating the receiving module and the sending-out module, but the sending-out module may be independently disposed on the opposite side of the molding module 3C of fig. 1 from the molding module 3B.

< B. structural example of the pressing unit 10

Next, a configuration example of the press unit 10 included in the molding module 3 of the resin molding apparatus 1 will be described.

Fig. 2 is a schematic diagram showing an example of the configuration (before mold clamping state) of the press unit 10 constituting the resin molding apparatus 1 according to the present embodiment. Fig. 3 is a schematic diagram showing an example of the configuration (mold clamping state) of the press unit 10 constituting the resin molding apparatus 1 according to the present embodiment.

Referring to fig. 2 and 3, the press unit 10 includes an upper fixed platen 17 and a movable platen 19. An upper die 18 is fixedly disposed on the lower surface of the upper fixed platen 17, and a lower die 11 is fixedly disposed on the upper surface of the movable platen 19. The upper die 18 and the lower die 11 incorporate heaters 20 as heating means. The upper die 18 and the lower die 11 are heated to a predetermined temperature (for example, about 180 ℃) by the heater 20.

A lead frame 15 before sealing is disposed in a predetermined region of the lower mold 11. The lead frame 15 before sealing has a lead frame body and a chip 21 mounted on the lead frame body. The terminals of the chip 21 and the terminals of the lead frame are electrically connected by wires 22.

The press unit 10 includes a mold clamping mechanism 23 for vertically moving the movable platen 19 in the paper plane. The mold clamping mechanism 23 moves up and down the movable platen 19 to change the distance between the upper mold 18 and the lower mold 11 (corresponding to the first mold and the second mold), thereby clamping (see fig. 3) and opening the mold between the upper mold 18 and the lower mold 11. That is, the mold clamping mechanism 23 changes the distance between the upper mold 18 and the lower mold 11.

The control unit 100 controls the up-and-down operation of the mold clamping mechanism 23. In this manner, the control unit 100 controls the mold mechanism 23, but may control other mechanisms constituting the resin molding apparatus 1. Regarding control of the press unit 10, the control unit 100 acquires the amount of strain detected by the strain gauge 152 provided on the support shaft of the mold clamping mechanism 23, and measures the force or pressure applied to the molding die by the mold clamping mechanism 23 at the time of mold clamping (hereinafter also referred to as "mold clamping force"). The control unit 100 gives a control command to the actuator 150 that drives the clamping mechanism 23, and acquires the elevation position of the movable platen 19 from the clamping mechanism 23. As described later, the control unit 100 controls the mold mechanism 23 based on input of a mold clamping force, a lifting position, and the like applied to the mold.

The mold clamping mechanism 23 may be implemented by any mechanism, and for example, an air cylinder, a toggle mechanism, or the like may be used. The mold clamping mechanism 23 is driven by the actuator 150, and outputs the elevation position as feedback.

In the resin molding apparatus 1 according to the present embodiment, the mold clamping mechanism 23 drives the lower mold 11 disposed under the gravity of the upper mold 18, but the lower mold 11 may be fixed to drive the upper mold 18, or both the upper mold 18 and the lower mold 11 may be driven.

When the mold clamping operation is performed by the press unit 10, the control unit 100 gives a command to the actuator 150. In response to a command from the control unit 100, the mold clamping mechanism 23 is driven to move the lower mold 11 fixed to the upper surface of the movable platen 19 upward. The resin sheets 16 supplied into the respective pots 14 are pressed by the plungers 24 in conjunction with the upward movement by the mold clamping mechanism 23. In the pressing process, the resin sheet 16 is heated, whereby the resin sheet 16 is melted to produce a flowable resin. As shown in fig. 3, the plunger 24 is continuously pressed, and thereby the flowable resin generated by melting flows into the cavity 26 through the resin passage 25.

Then, the flowable resin flowing into the inside of the cavity 26 is heated for a necessary time required for hardening, thereby forming a hardened resin. After the required time for curing has elapsed, the upper mold 18 and the lower mold 11 are opened, and the sealed lead frame sealed with the resin is released.

< C. example of configuration of control section 100

Next, a configuration example of the control unit 100 constituting the resin molding apparatus 1 will be described. The control section 100 performs at least control related to resin molding in the press unit 10. The control unit 100 may also perform control of any mechanism included in the resin molding apparatus 1.

The control unit 100 can be realized by using a control device such as a Programmable Logic Controller (PLC), or can be realized by using an industrial personal computer.

Fig. 4 is a schematic diagram showing an example of a hardware configuration of the control unit 100 constituting the resin molding apparatus 1 according to the present embodiment. Fig. 4 shows a typical example of a configuration of a control unit 100 using an industrial personal computer having a general architecture (architecture). The control unit 100 executes a general-purpose Operating System (OS) and a real-time (real-time) OS, respectively, thereby satisfying a Human-Machine Interface (HMI) function, a communication function, and a control function requiring real-time performance.

The control unit 100 includes an input unit 102, an output unit 104, a main memory 106, an optical Drive 108, a processor 110, a Hard Disk Drive (HDD) 120, a network interface 112, a clamping force measurement interface 114, and a clamping mechanism interface 116 as main components (components). These components are connected in such a manner that data can be exchanged with each other via an internal bus 118.

The input unit 102 is a member for receiving an operation from an operator, and typically includes a keyboard, a touch panel, a mouse, a track ball (track ball), and the like. The output unit 104 is a means for outputting the processing result and the like in the control unit 100 to the outside, and typically includes a display, a printer, various indicators (indicators), and the like. The main Memory 106 includes a Dynamic Random Access Memory (DRAM) or the like, and holds codes of programs executed in the processor 110 or various work data (work data) necessary for executing the programs.

The processor 110 is a processing main body that reads out a program stored in the HDD 120 and executes processing on input data. The processor 110 is configured to execute a general-purpose OS and various applications (applications) operating on the general-purpose OS, and a real-time OS and various applications operating on the real-time OS, respectively, in parallel. For example, the processor 110 may be implemented by any one of a configuration including a plurality of processors (a so-called "multiprocessor"), a configuration including a plurality of cores (cores) in a single processor (a so-called "multi-core"), and a configuration having features of both the multiprocessor and the multi-core.

The HDD 120 is a storage unit, and typically stores a general-purpose OS 122, a real-time OS 124, an HMI program 126, and a control program 128. The HMI program 126 acts within the execution environment of the general purpose OS 122 to primarily effect processing related to the exchange of operators. The control program 128 operates in an execution environment of the real-time OS 124, and controls each component constituting the resin molding apparatus 1.

Various programs executed by the control unit 100 are stored in a recording medium 108A such as a high-density Read-Only disk (DVD-ROM) and can be distributed. The content of the recording medium 108A is read by the optical drive 108 and mounted (install) on the HDD 120. That is, one aspect of the present invention includes a program for realizing the control unit 100 and some recording medium storing the program. As these recording media, in addition to optical recording media, magnetic recording media, magneto-optical recording media, semiconductor recording media, and the like can be used.

Fig. 4 illustrates a mode in which a plurality of programs are installed in HDD 120, but these programs may be integrated as one program or may be incorporated as a part of another program.

The network interface 112 exchanges data with an external device via a network.

The program installed on the HDD 120 may also be acquired from a server (server) via the network interface 112. That is, the program for realizing control unit 100 according to the present embodiment may be downloaded and installed in HDD 120 by any method.

The measurement value (strain amount) from the strain gauge 152 is input to the mold clamping force measurement interface 114. The mold clamping mechanism interface 116 receives an input of a lifting position from the mold clamping mechanism 23. Further, a command for raising and lowering the movable platen 19 is given to the actuator 150 from the clamping mechanism interface 116.

In fig. 4, a configuration example in which the controller 100 according to the present embodiment is realized by executing a program by the processor 110 is described, but the present invention is not limited to this, and a configuration according to the technical level of the time when the powder and granular material supply apparatus or the powder and granular material supply method according to the present invention is actually achieved can be suitably adopted. For example, a PLC, which is an industrial controller, may be used instead of a general-purpose computer. Alternatively, all or a part of the functions provided by the control unit 100 may be implemented by an integrated Circuit such as an Application Specific Integrated Circuit (ASIC), or may be implemented by a reprogrammable Circuit element such as a Field-Programmable Gate Array (FPGA). Further alternatively, the functions provided by the control unit 100 shown in fig. 4 may be realized by cooperation of a plurality of processing bodies. For example, a plurality of computers may be coupled to realize the functions provided by the control section 100.

The components shown in fig. 4 are not all necessary, and components that are not used in actual control, such as the optical drive 108, a mouse as an example of the input unit 102, and a printer as an example of the output unit 104, may be omitted as appropriate.

Summary of foreign object detection

Next, an outline of the detection of foreign matter by the press unit 10 of the resin molding apparatus 1 according to the present embodiment will be described.

Fig. 5 is a schematic view showing an example of mixing of foreign matter detected in the press unit 10 of the resin molding apparatus 1 according to the present embodiment. As shown in fig. 5, as an example of the contamination of foreign matter, a state is assumed in which a plurality of lead frames 15 before sealing are arranged between the upper mold 18 and the lower mold 11. When the upper mold 18 and the lower mold 11 are clamped together in a state where a plurality of lead frames 15 before sealing are arranged, an excessive clamping force is generated in the upper mold 18 and the lower mold 11, which may cause damage to the molding dies. Further, a decrease in productivity due to the occurrence of defective products is also expected.

In the present embodiment, the foreign matter is detected based on whether or not the mold clamping force exceeds a predetermined set value (hereinafter also referred to as a "foreign matter detection value") before the lower mold 11 is raised to a predetermined position (hereinafter referred to as a "foreign matter detection position") by the mold clamping mechanism 23. That is, the resin molding apparatus 1 detects a foreign object in the molding die based on the mold clamping force measured at the foreign object detection position during the molding operation.

Fig. 6 is a diagram for explaining the process of detecting foreign matter in the press unit 10 of the resin molding apparatus 1 according to the present embodiment. Referring to fig. 6, the mold clamping operation of the molding die by the press unit 10 includes a first stage P1 in which position control is performed and a second stage P2 in which pressure control is performed.

In the first stage P1, the control unit 100 gives an elevation command to the mold mechanism 23 so that the elevation position becomes the predetermined foreign object detection position. That is, the mold clamping mechanism 23 performs the elevation control based on the elevation position. In the second stage P2, the controller 100 gives an up command to the mold clamping mechanism 23 so that the mold clamping force becomes a predetermined value. That is, the mold clamping mechanism 23 performs lift control based on the mold clamping force. Fig. 6 shows an example in which the lower mold is raised during mold clamping, the object to be molded is brought into contact with the upper mold, and the mold clamping force is increased to the stop position of the lower mold.

The foreign matter detection is performed in the first stage P1 based on whether or not the mold clamping force measured in the above process exceeds the foreign matter detection value. As described later, the foreign matter detection position is set appropriately so as to be able to distinguish between the normal state and the foreign matter inclusion state, so that the mold clamping force does not exceed the foreign matter detection value until the foreign matter detection position is reached in the normal state. On the other hand, in the foreign matter mingled state, the mold clamping force exceeds the foreign matter detection value before reaching the foreign matter detection position.

In this way, the process of detecting the foreign matter by the control unit 100 includes the following processes: in the process of reducing the distance between the upper mold 18 and the lower mold 11 to the foreign matter detection position, the presence or absence of the foreign matter is determined based on whether or not the mold clamping force measured in the above-described process exceeds the foreign matter detection value. In the present embodiment, the presence or absence of the inclusion of foreign matter is determined based on the difference in the mold clamping force.

In a state where the distance between the upper mold 18 and the lower mold 11 is reduced to the foreign matter detection position, if the mold clamping force measured in the process of detecting the foreign matter does not exceed the foreign matter detection value, the control unit 100 proceeds to the second stage P2 to give a command to the mold clamping mechanism 23 so that the mold clamping force becomes a preset value.

By the processing in the first stage P1 and the second stage P2, the molding dies can be clamped with a predetermined clamping force.

< E. method for setting foreign object detection position

Next, a method of setting the foreign object detection position will be described. The foreign matter detection position is set for each molding die.

Fig. 7 is a schematic diagram for explaining a method of setting a foreign matter detection position of the resin molding apparatus 1 according to the present embodiment. Referring to fig. 7, in a state where the lead frame 15 before sealing is arranged in the molding dies (the upper die 18 and the lower die 11), the distance between the upper die 18 and the lower die 11 is reduced by moving the movable platen 19 upward, and the measured clamping force is monitored. When the mold clamping force exceeds the foreign object detection value, the raising of the movable platen 19 is stopped. A position obtained by subtracting a preset correction value (which may include a case where the correction value is zero) from the stop position of the movable platen 19 is set as the foreign object detection position. In a normal molding operation, foreign matter detection is performed based on a mold clamping force measured before reaching a set foreign matter detection position. The process of setting the foreign object detection position may be performed when the molding die is replaced.

Fig. 8 is a flowchart showing a procedure of setting a foreign matter detection position in the resin molding apparatus 1 according to the present embodiment. The steps of the flowchart shown in fig. 8 are typically realized by the processor 110 of the control unit 100 executing the HMI program 126 and the control program 128.

Referring to fig. 8, the control unit 100 determines whether or not to instruct a shift to the molding die replacement mode (step S100). The operator gives an instruction to shift to the mold replacement mode via the input unit 102 of the control unit 100. If the transition to the mold replacement mode is not instructed (NO in step S100), the process of step S100 is repeated.

When a shift to the mold replacement mode is instructed (YES in step S100), the control unit 100 notifies the output unit 104 or the like of the mold replacement mode (step S102). In this state, the operator replaces the molding die. When the replacement of the forming mold is completed, the operator instructs the end of the replacement mode of the forming mold.

The control unit 100 determines whether or not the completion of the mold replacement mode is instructed (step S104). If the end of the mold replacement mode is not instructed (no in step S104), the process of step S104 is repeated.

When the completion of the mold replacement mode is instructed (yes in step S104), the control unit 100 ends the notification in the mold replacement mode (step S106).

Then, the foreign object detection position setting process is started. Before starting the process of setting the foreign object detection position, the control unit 100 notifies the output unit 104 or the like that the foreign object detection position needs to be set (step S108). In this state, the operator disposes the lead frame 15 before sealing in the attached molding die. When the arrangement of the lead frame 15 before sealing is completed, the operator instructs to start the process of setting the foreign object detection position. The object to be molded may be disposed from the notification of step S108 to before the rising instruction of step S112 described later.

The control unit 100 determines whether or not the start of the foreign object detection position setting process is instructed (step S110). If the start of the foreign object detection position setting process is not instructed (no in step S110), the process of step S110 is repeated.

When the start of the process of setting the foreign object detection position is instructed (yes in step S110), the control unit 100 determines whether or not the raising of the clamping mechanism 23 is instructed (step S112). If the raising of the mold clamping mechanism 23 is not instructed (no in step S112), the process of step S112 is repeated.

When the mold clamping mechanism 23 is instructed to be raised (yes in step S112), the control unit 100 measures the mold clamping force while reducing the distance between the upper mold 18 and the lower mold 11 in a state where the lead frame 15 before sealing is arranged in the mold. More specifically, the control unit 100 gives an upward command to the mold clamping mechanism 23 (step S114), and starts monitoring the mold clamping force generated by the mold clamping mechanism 23 (step S116). Then, the control unit 100 determines whether or not the measured clamping force exceeds the foreign object detection value (step S118). The foreign matter detection value may be set in advance. If the mold clamping force measured in the above process does not exceed the foreign object detection value (no in step S118), the process of step S118 is repeated.

When the measured clamping force exceeds the foreign object detection value (yes in step S118), the control unit 100 gives a stop command to the clamping mechanism 23 (step S120), stores the elevation position in the state where the clamping mechanism 23 is stopped, and presents the stored elevation position to the operator from the output unit 104 or the like (step S122). That is, the control unit 100 acquires the elevation position (corresponding to the first position) of the clamping mechanism 23 at which the measured clamping force exceeds a predetermined foreign object detection value (corresponding to the first set value).

Then, the control unit 100 executes a process of expanding the distance between the upper mold 18 and the lower mold 11 when the measured clamping force exceeds the foreign object detection value. More specifically, the control unit 100 gives a lowering command to the clamping mechanism 23 (step S124), and stops the raising and lowering operation of the clamping mechanism 23 when the clamping mechanism 23 reaches the initial position (lowest position) (step S126).

Then, the control unit 100 determines whether or not the operator has performed the correction operation (step S128). If the operator does not perform the correction operation (no in step S128), the process of step S128 is repeated.

When the operator performs the correction operation (yes in step S128), the control unit 100 subtracts the correction value set in step S128 from the lifting/lowering position stored in step S122 to calculate the foreign object detection position (step S130). The correction value may be set to a default value in advance, or may be set manually by the operator. Further, the operator may arbitrarily change the default value set in advance.

That is, the foreign object detection position Hd can be expressed as the ascending/descending position H0 — the correction value Δ H using the ascending/descending position H0 and the correction value Δ H stored in step S122. The correction value Δ H corresponds to a limit for distinguishing the normal state from the foreign matter mingled state.

Then, the control unit 100 determines whether or not the operator has performed a setting determination operation of the foreign object detection position (step S132). If the operator does not perform the operation of setting the foreign object detection position (no in step S132), the process of step S132 is repeated. When the operator performs the operation of setting the foreign object detection position (yes in step S132), the control unit 100 sets the foreign object detection position calculated in step S130 in association with the currently installed molding die (step S134).

In step S134, when the setting described with reference to fig. 9 to be described later is not performed, the calculated foreign object detection position may not be associated with the currently installed molding die if it is not necessary.

In this way, the control unit 100 sets, as the foreign object detection position Hd, a position (the up-down position H0 — the correction value Δ H) obtained by correcting the acquired up-down position H0 (corresponding to the first position) of the mold clamping mechanism 23 by the correction value Δ H in the direction of increasing the distance between the upper mold 18 and the lower mold 11. Then, the control unit 100 ends the notification that the foreign object detection position needs to be set (step S136).

In the above procedure, the foreign object detection position setting process is completed. Based on the foreign matter detection position thus set, foreign matter detection based on the mold clamping force measured at the foreign matter detection position is performed in a normal molding operation.

Specifically, the lower mold on which the molding object is placed is raised and reaches the foreign object detection position set as described above, and then the mold clamping force measured at the position is acquired. A predetermined foreign material detection value is compared with a mold clamping force at a foreign material detection position, and when the mold clamping force exceeds the foreign material detection value, the molding operation is stopped and the lower mold is lowered. When the mold clamping force is lower than the foreign matter detection value, the lower mold is further raised to perform resin molding on the molding object. When the mold clamping force is equal to the foreign matter detection value, the molding operation may be stopped and the lower mold may be lowered as in the case where the mold clamping force exceeds the foreign matter detection value, or the lower mold may be raised to perform resin molding on the molding object as in the case where the mold clamping force is lower than the foreign matter detection value.

F, foreign matter detection value and correction value

In the above description, an example in which a foreign object detection value and a correction value used when a foreign object detection position is set are set in advance is shown. Since the foreign matter detection position is set for each molding die, the foreign matter detection value and the correction value may be set to values corresponding to the molding die.

Fig. 9 is a diagram showing an example of setting the foreign matter detection value and the correction value used in the resin molding apparatus 1 according to the present embodiment. In the set value table 200 shown in fig. 9, three types (large package, medium package, and small package) are defined as the molding die types 201, and a foreign object detection value 202 and a correction value 203 are set for each type.

In the set value table 200 shown in fig. 9, the foreign matter detection value and the correction value are set depending on the size of the package generated by singulation after the lead frame 15 is resin-sealed before sealing.

The control unit 100 may set the set value and the correction value according to the property of the molding die, with reference to the set value table 200 shown in fig. 9. Alternatively, the control unit 100 may present the respective sets of the foreign object detection values and the correction values set in the set value table 200 to the operator and receive a selection from the operator.

By making such a foreign matter detection value and correction value dependent on the properties of the lead frame 15 before sealing, etc., a more appropriate foreign matter detection position can be set.

In the embodiment, the following example is explained: the foreign matter detection value (set value) used when the up-down position (corresponding to the first position) is obtained in the setting of the foreign matter detection position is set to the same value as the foreign matter detection value used when the presence or absence of foreign matter is determined. In other words, an example in which the foreign object detection value used when determining the presence or absence of a foreign object is set to the same value as the foreign object detection value used when acquiring the up-down position is described.

However, when the foreign matter detection value used when the up-down position is acquired is the "first set value" or the "first set value of the mold clamping force", and the foreign matter detection value used when the presence or absence of foreign matter is determined is the "second set value" or the "second set value of the mold clamping force", the first set value and the second set value may be different from each other, for example, a value obtained by adjusting the first set value may be used as the second set value.

< G, attached notes >

The present embodiment includes the following technical ideas.

According to one embodiment, a resin molding apparatus for resin-molding a molding object using a molding die including a first die and a second die disposed to face each other can be provided. The resin molding apparatus includes: a mold clamping mechanism for changing the distance between the first mold and the second mold; and a control unit for controlling the mold mechanism. The control unit executes the following processing: in a state where the object to be molded is disposed in the molding die, a distance between the first die and the second die is reduced, and a clamping force, which is a pressure applied to the molding die by the clamping mechanism, is measured; acquiring a first position of a mold clamping mechanism of which the measured mold clamping force exceeds a preset first set value; setting a second position obtained by correcting the first position with the correction value as a foreign object detection position; and detecting a foreign object in the molding die based on the mold clamping force measured at the foreign object detection position during the molding operation.

The process of detecting foreign matter may also include the following processes: in the process of reducing the distance between the first die and the second die to the foreign matter detection position, the presence or absence of the foreign matter is determined based on whether or not the mold clamping force measured in the process exceeds a preset second set value.

The control unit may further execute the following processing: when the clamping force measured in the process of detecting the foreign object does not exceed the second set value in a state where the distance between the first die and the second die is reduced to the foreign object detection position, a command is given to the clamping mechanism so that the clamping force becomes a preset value.

The second set value may also be set to the same value as the first set value.

The control unit may further execute the following processing: when the mold clamping force measured in the process of detecting the foreign matter exceeds a second set value, the distance between the first mold and the second mold is enlarged.

The mold clamping mechanism may be configured to drive a second mold disposed under the gravity of the first mold.

The control unit may set the first set value and the correction value according to an attribute of the molding die.

According to another embodiment, there is provided a method of manufacturing a resin molded article, in which a molding object is resin-molded using a molding die including a first die and a second die disposed to face each other. The manufacturing method comprises the following steps: in a state where the object to be molded is disposed in the molding die, a clamping force, which is a pressure applied to the molding die by the clamping mechanism, is measured while the distance between the first die and the second die is reduced by the clamping mechanism; acquiring a first position of a mold clamping mechanism of which the measured mold clamping force exceeds a preset first set value; setting a second position obtained by correcting the first position with the correction value as a foreign object detection position; and detecting a foreign object in the molding die based on the mold clamping force measured at the foreign object detection position during the molding operation.

The step of detecting the foreign matter may include the steps of: in the process of reducing the distance between the first die and the second die to the foreign matter detection position, the presence or absence of the foreign matter is determined based on whether or not the mold clamping force measured in the process exceeds a preset second set value.

The manufacturing method may further include the steps of: when the clamping force measured in the process of detecting the foreign object does not exceed the second set value in a state where the distance between the first die and the second die is reduced to the foreign object detection position, a command is given to the clamping mechanism so that the clamping force becomes a preset value.

The second set value may also be set to the same value as the first set value.

The manufacturing method may further include the steps of: when the mold clamping force measured in the process of detecting the foreign matter exceeds a second set value, the distance between the first mold and the second mold is enlarged.

The mold clamping mechanism may be a second mold arranged under the gravity of the first mold.

The manufacturing method may further include a step of setting the first set value and the correction value in accordance with the property of the forming die.

< H. advantage >

As a typical method of setting the foreign matter detection position, one lead frame 15 before sealing is placed in a molding die, and a position that is in a predetermined state is obtained by manual operation, and two lead frames 15 before sealing are placed in the molding die, and a position that is in a predetermined state is obtained by manual operation. The intermediate value between the two positions thus obtained, or the like, may be set as the foreign matter detection position. In this setting method, there is a problem that the set value may be deviated due to the skill of the operator, and further, since the setting method is a manual operation, it takes a lot of time.

In contrast, according to the present embodiment, the foreign object detection position can be automatically set. Thus, the foreign object detection position can be set more accurately than in the case where the foreign object detection position is set by manual operation, and therefore highly accurate foreign object detection can be achieved. In addition, compared with the case where the foreign object detection position is set by manual operation, the time required to set the foreign object detection position can be shortened, and productivity can be improved.

The embodiments of the present invention have been described, but the embodiments disclosed herein are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is shown by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.