Resin Molding Apparatus and Method for Manufacturing Resin Molded Product

Abstract

To provide a resin molding device that has the function to wind a coating material around a resin material.SOLUTION: A resin molding device has a coating material winding mechanism 8 that winds a coating material 7 around the outer circumference of a resin material J, and a resin molding mechanism 10 that performs resin molding using the resin material J with the coating material 7 wound around it. The coating material winding mechanism 8 has a resin housing section 881 that houses the resin material J and a feed-out mechanism 83 that sends the coating material 7 into the resin housing section 81.SELECTED DRAWING: Figure 8

Description

Technical Field

[0001] The present invention relates to a resin molding apparatus and a method for manufacturing a resin molded product.

Background Art

[0002] As a resin molding method for performing resin molding using a resin material, there is a method of resin-sealing an object to be molded by extruding the resin material accommodated in a pot of a mold into a cavity of the mold by a plunger.

[0003] Here, resin dust is generated when the resin material accommodated in the pot is transported or attached to the pot. This resin dust not only has an adverse effect on the sealing equipment but also requires cleaning work. For this reason, as a means for preventing dust generated from the resin material, the resin pellets shown in Patent Document 1 are considered. This resin pellet forms a dust-proof film made of paste powder or wax on the surface to suppress the generation of resin dust.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, when the resin material in the pot is extruded into the cavity by a plunger, the melted resin material enters the sliding portion between the inner surface of the pot and the plunger, thereby generating resin scraps as residues.

[0006] In response to this problem, the inventor of the present application considers disposing a covering body that surrounds the resin material between the inner surface of the pot and the resin material, making it difficult for the melted resin material to enter the sliding portion between the inner surface of the pot and the plunger, and reducing resin scraps.

[0007] And as a configuration in which a covering body that surrounds the resin material is disposed between the inner surface of the pot and the resin material, before housing it in the pot, it is considered to wind the covering body around the resin material and then house the resin material with the covering body wound thereon in the pot.

[0008] Therefore, the present invention has been made to realize a specific configuration for disposing a covering body that surrounds the resin material between the inner surface of the pot and the resin material, and its main problem is to provide a function of automatically winding the covering body around the resin material in a resin molding apparatus.

Means for Solving the Problems

[0009] That is, the resin molding apparatus according to the present invention includes a covering body winding mechanism that winds a covering body around the outer peripheral surface of a resin material, and a resin molding mechanism that performs resin molding using the resin material with the covering body wound thereon, and the covering body winding mechanism is characterized by having a resin housing portion that houses the resin material and a feeding mechanism that feeds the covering body to the resin housing portion.

Effects of the Invention

[0010] According to the present invention configured as described above, it is possible to provide a function of automatically winding a covering body around a resin material in a resin molding apparatus.

Brief Description of the Drawings

[0011]

Figure 1

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Figure 7

Figure 8

Figure 9

Figure 10

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Figure 13

Embodiments for Carrying Out the Invention

[0012] Next, the present invention will be described in more detail with examples. However, the present invention is not limited by the following description.

[0013] As described above, the resin molding apparatus of the present invention includes a covering winding mechanism that winds a covering around the outer peripheral surface of a resin material, and a resin molding mechanism that performs resin molding using the resin material with the covering wound thereon. The covering winding mechanism is characterized by having a resin housing part that houses the resin material and a feeding mechanism that feeds the covering to the resin housing part.

[0014] In the case of this resin molding apparatus, since it is equipped with a coating winding mechanism for winding a coating around the outer peripheral surface of the resin material, it is possible to impart a function of automatically winding the coating around the resin material in the resin molding apparatus, and resin molding can be performed using the resin material with the coating wound thereon. As a result, a coating that surrounds the resin material is disposed between the inner surface of the pot and the resin material during resin molding, so that the resin material can be prevented from touching the inner surface of the pot, and resin scraps adhering to the inner surface of the pot can be reduced. Further, since the resin material is surrounded by the coating, even if it is a highly fluid resin such as resin for mold underfill (MUF) or clear resin, it becomes difficult for the molten resin material to penetrate into the sliding portion between the inner surface of the pot and the plunger, and resin scraps generated by the resin material penetrating into the sliding portion can be reduced. By reducing the resin scraps in this way, contamination during the next resin molding can be reduced, and the quality of the resin molded product can be improved; also, equipment troubles caused by resin scraps can be prevented, and the frequency of cleaning work can be reduced. Furthermore, by using the coating, an increase in the sliding resistance of the plunger can be prevented, so that stabilization of the quality of the resin molded product can be achieved, and the long life of the pot and the plunger can also be achieved.

[0015] As a specific embodiment for feeding the coating into the resin storage portion, it is desirable that the coating winding mechanism has a slit-shaped opening communicating with the resin storage portion, and the feeding mechanism feeds the coating into the resin storage portion from the opening.

[0016] In order to automatically feed a coating of a desired length into the resin storage portion, it is desirable that the feeding mechanism has a fixing portion for fixing the coating outside the resin storage portion and a cutting portion for cutting the coating fixed by the fixing portion, and the coating cut by the cutting portion is fed into the resin storage portion.

[0017] The covering is in the shape of a sheet, and the width dimension of the covering is such that it can cover the entire axial direction of the outer peripheral surface of the resin material. It is desirable that the length dimension of the covering cut by the cutting portion is such that it can wrap around the outer peripheral surface of the resin material one or more times. With this configuration, the entire outer peripheral surface of the resin material can be covered with the covering, and resin chips adhering to the inner surface of the pot can be further reduced.

[0018] As a specific embodiment of the feeding mechanism, it is desirable that the feeding mechanism has a roller for feeding the covering.

[0019] The feeding mechanism is provided at a distance along a predetermined feeding direction and has two rollers for feeding the covering. It is desirable that the fixing portion and the cutting portion are provided between the two rollers. With this configuration, the covering can be reliably fed to the fixing portion and the cutting portion by one roller, and the covering cut by the resin housing portion can be reliably fed by the other roller.

[0020] Furthermore, it is desirable that the resin molding apparatus of the present invention further includes a conveying mechanism for conveying the resin material in a state where the covering is wound around the resin molding mechanism. With this configuration, it is possible to automatically perform the operations from the winding operation of the covering by the covering winding mechanism to the resin molding operation by the resin molding mechanism.

[0021] The covering winding mechanism has a push portion for pushing out and delivering the resin material in a state where the covering is wound around the resin material conveying mechanism. It is desirable that a relief portion for avoiding interference with the push portion is formed in the resin housing portion. With this configuration, both the resin material and the covering can be reliably pushed out by the push portion and delivered to the resin material conveying mechanism.

[0022] In a configuration where a relief portion is formed in the resin housing portion, in order to prevent the relief groove from interfering with the movement of the covering body when the covering body is wound around the resin material, it is desirable that a guide surface for guiding the covering body is formed on the inner surface of the relief portion in the advancing direction of the covering body.

[0023] Furthermore, a method for manufacturing a resin molded product using the resin molding apparatus described above is also an aspect of the present invention.

[0024] <An embodiment of the present invention> Hereinafter, an embodiment of the resin molding apparatus according to the present invention will be described with reference to the drawings. Note that, for the sake of clarity, all the figures shown below are schematically drawn with appropriate omissions or exaggerations. The same reference numerals are given to the same components, and the description thereof will be omitted as appropriate.

[0025] <Basic configuration of the resin molding apparatus 100> The resin molding apparatus 100 of the present embodiment resin-molds a molding object W to which an electronic component Wx is connected by transfer molding using a resin material J.

[0026] Here, examples of the molding object W include a metal substrate, a resin substrate, a glass substrate, a ceramic substrate, a circuit board, a semiconductor substrate, a wiring board, a lead frame, etc., and the presence or absence of wiring is not a concern. Further, the resin material J for resin molding is, for example, a composite material containing a thermosetting resin, and the form of the resin material J is, for example, a tabular solid having a cylindrical shape. Further, examples of the electronic component Wx connected to the upper surface of the molding object W include electronic elements such as bare chips, resistor elements, capacitor elements, or those in which at least one of these electronic elements is resin-sealed.

[0027] Specifically, as shown in FIG. 1, the resin molding apparatus 100 includes a resin molding mechanism 10 for resin molding using a resin material J. The resin molding mechanism 10 includes a lower mold 2 (hereinafter referred to as the lower mold 2) in which a pot 21 for accommodating the resin material J is formed, and an upper mold 3 (hereinafter referred to as the upper mold 3) provided opposite to the lower mold 2 and having a cavity 31 into which the resin material J is injected, and a clamping mechanism (not shown) for clamping the lower mold 2 and the upper mold 3. The lower mold 2 is provided via a lower mold holding member 4 on a movable platen (not shown) that moves up and down by the clamping mechanism. The upper mold 3 is provided via an upper mold holding member (not shown) on an upper fixed platen (not shown). The lower mold holding member 4 has, for example, a heater plate, a heat insulating plate, or the like.

[0028] For example, a plurality of pots 21 are formed in the upper surface of the lower mold 2 so as to open. The pot 21 is constituted by a through hole 2H formed in the lower mold 2. The through hole 2H is formed, for example, by fitting a pot member 20 having a cylindrical shape made of cemented carbide or steel material into the lower mold 2. The pot 21 has a shape corresponding to the shape of the resin material J. In the present embodiment, since the resin material J is cylindrical, the pot 21 also has a circular cross-sectional shape accordingly. In addition, a mounting portion 22 for mounting the object to be molded W is formed on the upper surface of the lower mold 2.

[0029] Further, a cavity 31 for accommodating the electronic component Wx of the object to be molded W mounted on the mounting portion 22 of the lower mold 2 is formed on the lower surface (mold surface) of the upper mold 3. Further, a caul portion 32, which is a recess, is formed in a portion of the lower surface of the upper mold 3 that faces the pot 21 of the lower mold 2, and a runner portion 33 for connecting the caul portion 32 and the cavity 31 is formed.

[0030] The resin molding mechanism 10 includes a plunger unit 5 having a plurality of plungers 51 for extruding the resin material J accommodated in the plurality of pots 21 of the lower mold 2, and a drive mechanism 6 for moving the plunger unit 5 so that the plungers 51 move forward and backward within the pots 21.

[0031] The plunger unit 5 is provided below the lower mold 2, and the plunger 51 is inserted into the through hole 2H of the lower mold 2. And the upper surface of the plunger 51 constitutes the bottom surface of the pot 21 of the lower mold 2. Further, the plunger 51 presses the resin material J melted by heating in the pot 21 from the pot 21 toward the upper mold 3.

[0032] The drive mechanism 6 relatively moves the plunger unit 5 with respect to the lower mold 2, whereby the plunger 51 moves forward and backward (moves up and down) in the pot 21. The drive mechanism 6 of the present embodiment is provided on the side opposite to the lower mold 2 with respect to the plunger unit 5 (the lower side of the plunger unit 5). Here, as the drive mechanism 6, for example, a combination of a servo motor and a ball screw mechanism, a combination of an air cylinder or a hydraulic cylinder and a rod, or the like can be used.

[0033] When the plunger unit 5 is raised with the lower mold 2 and the upper mold 3 clamped by the clamping mechanism, the resin material J melted by the heat of a heater (not shown) provided in the resin molding mechanism 10 is injected into the cavity 31. Thereby, the electronic component Wx of the object to be molded W accommodated in the cavity 31 is resin-sealed.

[0034] <Characteristic part of the method for manufacturing the resin molded product P> Next, the characteristic part of the method for manufacturing the resin molded product P using the above resin molding apparatus 100 will be described.

[0035] As shown in FIG. 1, when the resin material J is accommodated in the pot 21 of the lower mold 2, the covering body 7 is disposed between the inner surface of the pot 21 and the resin material J so that the resin material J does not contact the inner surface of the pot 21.

[0036] This covering body 7 surrounds the entire circumference of the resin material J while opening the direction in which the resin material J is extruded in the pot 21. Specifically, the covering body 7 surrounds the entire outer circumferential surface of the resin material J without covering the upper surface of the resin material J in the pot 21.

[0037] This covering 7 is a consumable that is discarded every time resin molding is performed. Examples thereof include those made of paper, resin, cellulose, woven fabric, non-woven fabric, or a composite material thereof. Note that examples of the composite material include a resin film containing a filler, a laminate of paper and a resin film such as a heat-resistant film of 10 μm or less, a paper coated with resin, a paper impregnated with resin, and a paper made by mixing pulp and resin fibers and then forming them into a sheet. These coverings 7 are made of a material that does not melt or thermally decompose at the molding temperature (for example, about 170°C) for resin encapsulation with the resin material J.

[0038] Specifically, as shown in FIG. 2, the covering 7 is, for example, in the form of a rectangular sheet and is disposed in the pot 21 in a state of being wound around the outer peripheral surface of the resin material J. Here, as shown in the development view of FIG. 2(d), the width dimension L1 of the covering 7 is a dimension that covers the entire axial direction of the outer peripheral surface of the resin material J, and the length dimension L2 of the covering 7 is a dimension that can be wound around the outer peripheral surface of the resin material J one or more times. For example, the width dimension L1 of the covering 7 is about 0.5 to 3 mm longer than the width dimension of the resin material J, and the length dimension L2 of the covering 7 is 1.1 to 1.5 times the circumference of the outer periphery of the resin material J when the outer periphery of the resin material J is one turn. By adopting such a configuration in which the sheet-like covering 7 is wound around the resin material J, the configuration of the covering 7 can be simplified and the processing cost can be reduced.

[0039] Also, the thickness of the covering 7 is larger than the clearance (gap) between the inner surface of the pot 21 and the plunger 51, and the covering 7 itself is configured not to enter the sliding portion between the inner surface of the pot 21 and the plunger 51. For example, when the clearance is 10 μm, the thickness of the covering 7 is 50 μm.

[0040] The covering body 7 is configured to closely adhere to the inner surface of the pot 21. Specifically, the covering body 7 is configured such that the inner pressure applied by the resin material J melted or softened in the pot 21 causes the covering body 7 to closely adhere to the inner surface of the pot 21. In the present embodiment, the covering body 7 is wound around the resin material J and is not restricted in the circumferential direction, and the resin material J and the covering body 7 are not in close contact with each other, and a gap may be formed therebetween. Thus, the covering body 7 is likely to expand in the radial direction due to the inner pressure applied by the melted or softened resin material J, and is likely to closely adhere to the inner surface of the pot 21. The inner pressure applied by the melted or softened resin material J is mainly the pressure generated when the melted or softened resin material J is pushed by the plunger 51 and spreads in the circumferential direction, or when the melted or softened resin material J is pushed by the plunger 51 and the caulking portion 32 of the upper mold 3 and spreads in the circumferential direction during the injection operation by the plunger 51.

[0041] By configuring the covering body 7 to closely adhere to the inner surface of the pot 21 in this way, the covering body 7 closes the sliding portion between the inner surface of the pot 21 and the plunger 51, making it more difficult for the melted resin material J to penetrate further through the sliding portion. Also, since the covering body 7 closely adheres to the inner surface of the pot 21 due to the inner pressure applied by the resin material J melted or softened in the pot 21, it is not necessary to closely adhere the covering body 7 to the inner surface of the pot 21 when arranging the covering body 7 in the pot 21, and the covering body 7 can be easily arranged in the pot 21.

[0042] <Configuration for automating the method of manufacturing the resin molded product P> As a configuration for automating the method of manufacturing the resin molded product P described above, the resin molding apparatus 100 of the present embodiment further includes a covering body winding mechanism 8 that winds the covering body 7 around the outer circumferential surface of the resin material J, and a resin material conveying mechanism 9 that conveys the resin material J with the covering body 7 wound thereon to the resin molding mechanism 10, as shown in FIGS. 3 to 6. The resin molding mechanism 10 performs resin molding using the resin material J with the covering body 7 wound thereon. As shown in FIG. 3, the covering body winding mechanism 8, the resin material conveying mechanism 9, and the resin molding mechanism 10 are controlled by the control unit COM.

[0043] <Cover Winding Mechanism 8> As shown in FIGS. 4 to 6, the cover winding mechanism 8 feeds out the cover 7 from one side in the circumferential direction with respect to the columnar resin material J and winds the cover 7 around the outer circumferential surface of the resin material J. Hereinafter, the resin material J with the cover 7 wound around its outer circumferential surface is referred to as the "covered resin material J".

[0044] Specifically, as shown in FIGS. 4 to 6, the cover winding mechanism 8 includes a cover winding jig 80 and a push portion 84. The cover winding jig 80 has a resin housing portion 81 for housing the resin material J, a slit-shaped opening 82 communicating with the resin housing portion 81, and a feeding mechanism 83 for feeding out the cover 7 from the opening 82 to the resin housing portion 81.

[0045] The resin housing portion 81 and the slit-shaped opening 82 are formed in the cover winding jig 80. Here, the resin housing portion 81 houses the resin material J in a posture in which the central axis of the resin material J is along the horizontal direction (lying down state), and has a housing space having a substantially cylindrical shape. Further, the slit-shaped opening 82 is formed in the upper part of the resin housing portion 81, is connected to the upper part of the resin housing portion 81, and opens on the upper surface of the cover winding jig 80. The width dimension of this opening 82 is larger than the width dimension of the cover 7.

[0046] Furthermore, on the upper surface of the cover winding jig 80, a linear guide groove (concave groove) 80M is formed which extends along a predetermined feeding direction SD and guides the cover 7 to the opening 82. As shown in FIGS. 4 and 5, a feeding table 85 for feeding out the cover 7 to the cover winding jig 80 is connected to the cover winding jig 80. A linear guide groove (concave groove) 85M for guiding the cover 7 to the cover winding jig 80 is also formed in this feeding table 85.

[0047] As shown in FIGS. 4, 5 and 7, the feeding mechanism 83 has a fixing portion 831 for fixing the cover 7 outside the resin housing portion 81, and a cutting portion 832 for cutting the cover 7 fixed by the fixing portion 831, and feeds out the cover 7 cut by the cutting portion 832 to the resin housing portion 81.

[0048] The fixing part 831 is for fixing the covering body 7 when cutting the covering body 7 by the cutting part 832. Specifically, the fixing part 831 fixes the covering body 7 by adsorbing it, and has an adsorption hole 831a opening on the upper surface of the covering body winding jig 80 and a suction mechanism (not shown) such as a vacuum pump or a vacuum ejector for sucking air from the adsorption hole 831a. Further, as shown in FIGS. 4 and 5, the fixing part 831 of the present embodiment fixes the covering body 7 on both sides sandwiching the cutting position CP by the cutting part 832, and the adsorption holes 831a are provided on both sides sandwiching the cutting position CP by the cutting part 832.

[0049] The cutting part 832 cuts the covering body 7 fixed by the fixing part 831, and moves in the width direction of the covering body 7 (the direction perpendicular to the feeding direction SD of the covering body 7 on the horizontal plane) to cut the covering body 7 (see FIG. 7(c)). Specifically, the cutting part 832 has a cutting blade 832a for cutting the covering body 7 and a moving mechanism (not shown) for moving the cutting blade 832a forward and backward. The position where the cutting blade 832a passes through by this moving mechanism becomes the cutting position CP. Further, in the covering body winding jig 80, a slit 80S is formed at the cutting position CP where the cutting blade 832a passes through. The length dimension of the covering body 7 cut by this cutting part 832 is a dimension that can wind the outer peripheral surface of the resin material J one or more times. Note that the covering body 7 may be cut by moving the cutting blade 832a up and down with respect to the covering body 7.

[0050] And, as shown in FIGS. 4, 5, and 7, the feeding mechanism 83 is provided apart along a predetermined feeding direction SD and has two rollers 833, 834 for feeding the covering body 7. The fixing part 831 and the cutting part 832 are provided between these two rollers 833, 834. Hereinafter, among the two rollers 833, 834, the roller located on the rear side in the feeding direction SD is the insertion-side roller 833, and the roller located on the front side in the feeding direction SD is the winding part-side roller 834.

[0051] The insertion-side roller 833 feeds the covering 7 to the fixing part 831 and the cutting part 832, and feeds the covering 7 until the tip of the fed covering 7 reaches the winding part-side roller 834 (see Fig. 7(b)). Further, the winding part-side roller 834 inserts the covering 7 cut by the cutting part 832 through the opening 82 and feeds it to the resin accommodating part 81 (see Figs. 6(a) and 7(d)). Note that both the insertion-side roller 833 and the winding part-side roller 834 are rotated by a driving part (not shown) such as a motor.

[0052] As shown in Fig. 6, the covering 7 fed to the resin accommodating part 81 by the winding part-side roller 834 travels more than one round inside the resin accommodating part 81 while deforming along the inner peripheral surface of the resin accommodating part 81 and becomes cylindrical. When the resin material J is previously accommodated in the resin accommodating part 81, the covering 7 travels between the inner peripheral surface of the resin accommodating part 81 and the outer peripheral surface of the resin material J, and the covering 7 is wound one or more rounds around the outer peripheral surface of the resin material J, and the resin material J is packaged by the covering 7 (see Fig. 6(b)).

[0053] Further, as shown in Figs. 4, 5, and 7, the covering winding mechanism 8 has a push part 84 that pushes out and delivers the covered resin material J to the conveying mechanism 9. This push part 84 delivers the covered resin material J in a lying-down state in the resin accommodating part 81 to the conveying mechanism 9 by pushing it along the central axis direction. Specifically, as shown in Figs. 4 and 5, the push part 84 has a push member 841 that pushes out both the resin material J and the covering 7, and a driving part 842 that moves the push member 841 forward and backward. Note that as the driving part 842, for example, a combination of a servo motor and a ball screw mechanism, a combination of an air cylinder or a hydraulic cylinder and a rod, or the like can be used.

[0054] The push member 841 has a shape that can push out both the resin material J and the covering 7 without interfering with the resin accommodating part 81, and for example, has a flat plate shape (see Fig. 4).

[0055] Here, as shown in FIG. 6, in the resin housing portion 81, a relief portion 81a is formed to avoid interference with the push member 841. This relief portion 81a is formed on the inner peripheral surface of the resin housing portion 81 along the moving direction of the push member 841. And on the inner surface of this relief portion 81a, when the covering body 7 is sent out from the opening portion 82 and advances in the resin housing portion 81, a guide surface 81x (inducing taper surface 81x) for guiding the covering body 7 with respect to the advancing direction of the covering body 7 is formed so as not to obstruct it. In FIG. 6, the guide surface 81x is formed in a planar shape so as to approach the resin material J as it goes in the advancing direction of the covering body 7, but it may also be a curved surface formed so as to approach the resin material J as it goes in the advancing direction of the covering body 7.

[0056] <Resin material conveying mechanism 9> As shown in FIG. 8, the resin material conveying mechanism 9 conveys the covered resin material J to the resin molding mechanism 10 and stores the covered resin material J in the pot 21 of the lower mold 2.

[0057] As shown in FIG. 8, the resin material conveying mechanism 9 of the present embodiment includes a first conveying portion 91 that receives the covered resin material J from the covering body winding mechanism 8, a second conveying portion 92 that receives the covered resin material J from the first conveying portion 91, and a conveying and housing portion 93 that receives the covered resin material J from the second conveying portion 92 and stores it in the pot 21.

[0058] In FIG. 8, (a) shows the delivery state from the covering body winding mechanism 8 to the first conveying portion 91, (b) shows the delivery state from the first conveying portion 91 to the second conveying portion 92, (c) shows the delivery state from the second conveying portion 92 to the conveying and housing portion 93, and (d) shows the delivery state from the conveying and housing portion 93 to the pot 21.

[0059] The first conveying unit 91 conveys the coated resin material J from the covering body winding mechanism 8 to the second conveying unit 92, and has one or a plurality of accommodating parts 91a for accommodating the coated resin material J. Since the resin material J is cylindrical, this accommodating part 91a has an accommodating space with a circular cross-sectional shape accordingly. This accommodating part 91a is formed in the first accommodating member 911. As shown in FIG. 9, the accommodating part 91a of the first conveying unit 91 is formed in the first accommodating member 911 so as to open on the mutually facing surfaces. Then, with the first accommodating member 911 positioned on the side of the covering body winding mechanism 8 (see FIG. 8(a)), the coated resin material J enters from the opening formed on one surface. Further, the first accommodating member 911 moves to the delivery position to the second conveying unit 92 by a moving mechanism (not shown) (see FIG. 8(b)), and in this state, the coated resin material J is discharged from the opening formed on the other surface.

[0060] Here, as shown in FIG. 9, in the accommodating part 91a of the first conveying unit 91, the inner diameter of the opening, which is the end of the accommodating part 91a on the side where the coated resin material J is inserted, is configured to increase as it goes toward the opening side. Here, a tapered surface 91b is formed in the opening. With this configuration, when accommodating the coated resin material J, the covering body 7 is less likely to be caught by the opening, and can be smoothly accommodated in the accommodating part 91a. Further, it is possible to prevent the end of the covering body 7 from being bent and a portion not covered on the outer peripheral surface of the resin material J from occurring.

[0061] Further, as shown in FIG. 8(b), the first conveying unit 91 has a push unit 912 that extrudes and delivers the coated resin material J from the storage unit 91a of the first storage member 911 to the second conveying unit 92. This push unit 912 delivers the coated resin material J to the second conveying unit 92 by extruding it along the central axis direction. Specifically, the push unit 912 has a push member 912a that extrudes both the resin material J and the coating 7, and a drive unit (not shown) that moves the push member 912a forward and backward. The push member 912a has a shape that can extrude both the resin material J and the coating 7, and for example, has a flat plate shape. Further, a slit 911S is formed in the first storage member 911 so that both the resin material J and the coating 7 can be pushed out by this flat plate-shaped push member 912a. Further, a plurality of coated resin materials J are collectively delivered to the second conveying unit 92 by this push member 912a.

[0062] As shown in FIG. 8, the second conveying unit 92 conveys the coated resin material J from the first conveying unit 91 to the conveying and storage unit 9C, and like the first conveying unit 91, has one or a plurality of storage units 92a (see FIG. 9) for storing the coated resin material J. Since the resin material J is cylindrical, this storage unit 92a has a storage space with a circular cross-section corresponding thereto. This storage unit 92a is formed in the second storage member 921. The coated resin material J is taken in and out of the storage unit 92a of the second conveying unit 92 through an opening formed on one surface in the second storage member 921.

[0063] Here, as shown in FIG. 9, in the storage unit 92a of the second conveying unit 92, the inner diameter of the opening, which is the end of the storage unit 92a on the side where the coated resin material J is put in, is configured to increase toward the opening side. Here, a tapered surface 92b is formed in the opening. With this configuration, when the coated resin material J is stored, the coating 7 is less likely to be caught by the opening, and can be smoothly stored in the storage unit 92a. Further, it is possible to prevent the end of the coating 7 from being bent and a portion that is not covered on the outer peripheral surface of the resin material J from occurring.

[0064] Further, the second conveying unit 92 has a push unit 922 that extrudes and delivers the coated resin material J from the storage unit 92a of the second storage member 921 to the second conveying unit 92. This push unit 922 delivers the coated resin material J to the conveying and storage unit 93 by extruding it upward along the central axis direction. Here, the conveying and storage unit 93 is provided above the second conveying unit 92. The second conveying unit 92 receives the resin material J from the first conveying unit 91 in a horizontal state (see Fig. 8(b)), and delivers the resin material J to the conveying and storage unit 93 in an upright state rotated 90 degrees (see Fig. 8(c)). Note that the rotation of the second conveying unit 92 can be performed by a driving unit (not shown) such as a motor.

[0065] Specifically, the push unit 922 has a push member 922a that extrudes both the resin material J and the coating 7, and a driving unit 922b that moves the push member 922a forward and backward. The push member 922a has a shape that can extrude both the resin material J and the coating 7. For example, it has a flat plate shape. Also, similar to the first storage member 911, the second storage member 921 is formed with a slit (not shown) through which both the resin material J and the coating 7 can be pushed by the flat plate-shaped push member 922a. Further, a plurality of coated resin materials J are collectively delivered to the conveying and storage unit 93 by this push member 922a.

[0066] As shown in Fig. 8, the conveying and accommodating unit 93 conveys and inputs the resin material J that has been coated from the second conveying unit 92 into the pot 21. Similar to the first conveying unit 91, it has one or a plurality of accommodating portions 93a (see Figs. 10 and 11) for accommodating the coated resin material J. Since the resin material J is cylindrical, the accommodating portion 93a has an accommodating space with a circular cross-sectional shape accordingly. This accommodating portion 93a is formed in the third accommodating member 931. The coated resin material J is taken in and out through an opening formed on the lower surface in the third accommodating member 931 for the accommodating portion 93a of the conveying and accommodating unit 93. Further, as shown in Figs. 10(b) and 11(b), the third accommodating member 931 is provided with a holding shutter 932 for temporarily holding the coated body 7 and the resin material J accommodated in the accommodating portion 93a so that they do not fall. Note that the position where the holding shutter 932 is provided may be any position where the coated body 7 and the resin material J can be held with respect to the accommodating portion 93a. Furthermore, the third accommodating member 931 is moved to a delivery position to the pot 21 (here, the position where the accommodating portion 93a and the pot 21 are arranged vertically) by a moving mechanism (not shown) (see Figs. 8(d), 10, and 11).

[0067] Here, as shown in Figs. 10 and 11, in the accommodating portion 93a of the conveying and accommodating unit 93, the inner diameter of the opening, which is the end of the accommodating portion 93a on the side where the coated resin material J is pushed in, is configured to increase as it goes toward the opening side. Here, a tapered surface 93b is formed in the opening. With this configuration, when the coated resin material J is accommodated, the coated body 7 is less likely to be caught by the opening, and it can be smoothly accommodated in the accommodating portion 93a. Also, it can prevent the end of the coated body 7 from being bent and a portion that is not covered on the outer peripheral surface of the resin material J from occurring.

[0068] In addition, the conveying and accommodating unit 93 has a push unit 933 that extrudes and delivers the coated resin material J from the accommodating portion 93a of the third accommodating member 931 to the pot 21. This push unit 933 inputs the coated resin material J into the pot 21 by extruding it downward along the central axis direction. That is, the resin material J is inserted into and taken out from the opening portion of the accommodating portion 93a configured to become larger as it goes toward the opening side. Here, the accommodating portion 93a of the conveying and accommodating unit 93 is positioned above the pot 21, and both the coating body 7 and the resin material J are pushed downward by the push unit 933 to accommodate the coated resin material J in the pot 21. When accommodating the coated resin material J in the pot 21 by the push unit 933, the holding shutter 932 is opened (see Fig. 11(b)). In Fig. 11(b), the holding shutter 932 is configured to move in a direction orthogonal to the arrangement direction of the pots 21 (or the accommodating portion 93a), but it may also be configured to move in other directions (for example, the arrangement direction of the pots 21 (or the accommodating portion 93a), etc.).

[0069] Specifically, the push unit 933 has a push member 933a that extrudes both the resin material J and the coating body 7, and a drive unit (not shown) that moves the push member 933a forward and backward. The push member 933a has a shape that can extrude both the resin material J and the coating body 7. For example, it has a flat plate shape. In detail, the push member 933a has push end portions 933a1 each having a flat plate shape divided for each pot 21, and the upper portions of the plurality of push end portions 933a1 are connected to each other, and both the resin material J and the coating body 7 can be extruded for each pot 21. Further, in the third accommodating member 931, slits 933s (see Figs. 10 and 11) through which both the resin material J and the coating body 7 can be pushed are formed by the flat plate-shaped push end portions 933a1. Also, a plurality of coated resin materials J are collectively delivered to the pot 21 by this push member 933a.

[0070] Also, as shown in FIGS. 10 and 11, a protruding portion 933a2 for pushing the resin material J is formed on the surface (lower surface) that pushes the covering 7 and the resin material J at the push end portion 933a1. With this configuration, compared to the case where the surface (lower surface) that pushes the covering 7 and the resin material J at the push end portion 933a1 is a flat surface, it is possible to make it difficult to damage the covering 7. Incidentally, when the surface (lower surface) that pushes the covering 7 and the resin material J at the push end portion 933a1 is a flat surface, the shape of the push member 933a is simple and easy to design, and the cost can be suppressed.

[0071] <Overall process of the method for manufacturing the resin molded product P> Next, an example of the operation of the resin molding apparatus 100 will be described. In the present embodiment, all operations and controls, such as the covering winding operation of the covering winding mechanism 8, the resin material conveying operation of the resin material conveying mechanism 9, and the resin molding operation of the resin molding mechanism 10, are performed by the control unit COM (see FIG. 3).

[0072] <Covering winding operation> As shown in FIG. 7(a), the covering 7 is sent along the guide groove 85 of the feed table 85 to the insertion side roller 833 provided on the covering winding jig 80. As a result, the covering 7 is sandwiched between the upper surface of the covering winding jig 80 and the insertion side roller 833.

[0073] Then, as shown in FIG. 7(b), the insertion side roller 833 is rotated to send the covering 7 to the winding portion side roller 834. As a result, the tip portion of the covering 7 is sandwiched between the upper surface of the covering winding jig 80 and the winding portion side roller 834.

[0074] Next, as shown in FIG. 7(c), the covering 7 is adsorbed by the fixing portion 831 and fixed to the upper surface of the covering winding jig 80. After the covering 7 is fixed to the upper surface of the covering winding jig 80, the cutting portion 832 is moved forward and backward to cut the covering 7. By this cutting, the length dimension of the covering 7 sandwiched between the winding portion side rollers 834 becomes a dimension that can wrap around the outer peripheral surface of the resin material J one or more times.

[0075] After the covering 7 is cut by the cutting part 832, the adsorption of the covering 7 by the fixing part 831 is released.

[0076] Also, in parallel with each of the above operations, or before and after each of the above operations, a resin material J is accommodated in the resin accommodation part 81 of the covering winding jig 80 by a resin material supply part (not shown) (see Fig. 7(c)).

[0077] Then, as shown in Fig. 7(d), the roller 834 on the winding part side is rotated, and the cut covering 7 is inserted from the opening 82 and sent out into the resin accommodation part 81. As a result, the covering 7 advances between the inner peripheral surface of the resin accommodation part 81 and the outer peripheral surface of the resin material J (see Fig. 6(a)), and the covering 7 is wound around the outer peripheral surface of the resin material J one or more times, and the resin material J is packaged by the covering 7 (see Fig. 6(b)).

[0078] After the covering 7 is wound around the resin material J, as shown in Fig. 7(e), the push part 84 pushes the covering 7 and the resin material J, and delivers the covered resin material J to the accommodation part 91a of the first conveying part 91 (see Fig. 8(a)). When the first conveying part 91 has a plurality of accommodation parts 91a, the above operation is repeated to deliver the covered resin material J to the plurality of accommodation parts 91a.

[0079] <Conveying operation> After receiving the covered resin material J in the state shown in Fig. 8(a), the first conveying part 91 moves to the delivery position to the second conveying part 92 as shown in Fig. 8(b). At this delivery position, the accommodation part 91a of the first conveying part 91 and the accommodation part 92a of the second conveying part 92 are in a state of facing each other in the horizontal direction. Then, the push part 912 of the first conveying part 91 horizontally extrudes the covered resin material J accommodated in the accommodation part 91a and delivers it to the accommodation part 92a of the second conveying part 92.

[0080] Next, after receiving the coated resin material J, the second transfer unit 92 rotates 90 degrees and stands up as shown in FIG. 8(c). In this state, the housing portion 92a of the second transfer unit 92 and the housing portion 93a of the transfer housing unit 93 face each other in the vertical direction. Then, the push portion 922 of the second transfer unit 92 pushes the coated resin material J accommodated in the housing portion 92a upward and delivers it to the housing portion 93a of the transfer housing unit 93. After receiving the coated resin material J in the housing portion 93a, the transfer housing unit 93 closes the holding shutter 932 to hold the coating body 7 and the resin material J so that they do not fall.

[0081] After receiving and holding the coated resin material J, the transfer housing unit 93 moves to the loading position into the pot 21 as shown in FIG. 8(d). At this loading position, the housing portion 93a of the transfer housing unit 93 and the pot 21 face each other in the vertical direction (see FIG. 10). Then, while the holding shutter 932 of the transfer housing unit 93 opens, the push portion 933 of the transfer housing unit 93 pushes out at least the coating body 7 among the coated resin materials J accommodated in the housing portion 93a and accommodates it in the pot 21 (see FIG. 11). In the present embodiment, by pushing out both the coating body 7 and the resin material J from the push portion 933, the coating body 7 can be surely pushed to the bottom of the pot 21. In the present embodiment, since the width dimension L1 of the coating body 7 is about 0.5 to 3 mm longer than the width dimension of the resin material J, both the coating body 7 and the resin material J can be placed on the bottom surface of the pot 21 without significant damage together with the resin material J that falls by its own weight. Through the above series of operations, the coated resin material J is accommodated in the pot 21.

[0082] <Resin molding operation> By the above operation, the resin material J and the coating body 7 are accommodated in the pot 21, and as shown in FIG. 12(a), a molding object W is mounted on the mounting portion 22 of the lower mold 2 using another molding object transfer mechanism (not shown).

[0083] Then, as shown in FIG. 12(b), the upper mold 3 and the lower mold 2 are clamped to sandwich the object to be molded W between the upper mold 3 and the lower mold 2. At this time, the electronic component Wx of the object to be molded W is in a state of being accommodated in the cavity 31 of the upper mold 3.

[0084] Then, the resin material J melted in the pot 21 is extruded by the plunger 51. As a result, as shown in FIG. 12(c), the melted resin material J passes through the gate portion 32 and the runner portion 33 of the upper mold 3 and is introduced into the cavity 31.

[0085] Then, as shown in FIG. 13(a), by heating the melted resin material J for the required time necessary for curing, the resin material J is cured to form a cured resin. As a result, the electronic component Wx in the cavity 31 and the surrounding substrate are encapsulated in a cured resin (sealing resin) molded corresponding to the shape of the cavity 31.

[0086] Next, after the elapse of the required time necessary for curing, as shown in FIG. 13(b), the upper mold 3 and the lower mold 2 are opened, and the sealed substrate (resin molded product P) is demolded together with the unnecessary resin J1 and conveyed integrally. Here, the unnecessary resin J1 is composed of the resin remaining in the gate portion 32 (gate J11) and the resin remaining in the runner portion 33 (runner J12). Then, in another space away from the molding die (upper mold 3 and lower mold 2), as shown in FIG. 13(c), the unnecessary resin J1 is removed from the resin molded product P, and the unnecessary resin J1 is discarded. Here, after resin molding, the coating 7 remains in the gate portion 32 or the runner portion 33 and is included in the unnecessary resin J1 (gate J11 or runner J12) remaining in the gate portion 32 and the runner portion 33, and is discarded together with the unnecessary resin J1.

[0087] <Effects of this Embodiment> According to the resin molding apparatus 100 of the present embodiment, since it is provided with a covering body winding mechanism 8 for winding the covering body 7 around the outer peripheral surface of the resin material J, the resin molding apparatus 100 can be provided with a function of automatically winding the covering body 7 around the resin material J, and resin molding can be performed using the resin material J with the covering body 7 wound thereon. As a result, during resin molding, the covering body 7 surrounding the resin material J is disposed between the inner surface of the pot 21 and the resin material J, so that the resin material J can be prevented from touching the inner surface of the pot 21, and resin scraps adhering to the inner surface of the pot 21 can be reduced. Further, since the resin material J is surrounded by the covering body 7, even if it is a highly fluid resin such as a resin for mold underfill (MUF) or a clear resin, it is difficult for the molten resin material J to penetrate into the sliding portion between the inner surface of the pot 21 and the plunger 51, and resin scraps generated by the resin material J penetrating into the sliding portion can be reduced. Here, since the covering body 7 is open in the direction in which the resin material J is extruded, it does not interfere with the extrusion of the resin material J by the plunger 51.

[0088] By reducing the resin scraps in this way, contamination during the next resin molding can be reduced, and the quality of the resin molded product P can be improved. Further, equipment troubles caused by resin scraps can be prevented, and the frequency of cleaning work can also be reduced. Furthermore, by using the covering body 7, an increase in the sliding resistance of the plunger 51 can be prevented, so that the quality of the resin molded product P can be stabilized and the long life of the pot 21 and the plunger 51 can also be realized.

[0089] Further, the covering body winding mechanism 8 of the present embodiment is configured to wind the covering body 7 in a state where the resin material J is accommodated in the resin accommodating portion 81 (accommodating space having a cylindrical shape), and the covering body 7 can be reliably wound regardless of the dimensional tolerance in the diameter of the resin material J.

[0090] <Other modified embodiments> Note that the present invention is not limited to the above embodiment.

[0091] For example, in the above-described embodiment, after the resin material J was accommodated in the resin housing portion 81, the covering body 7 was inserted into and wound around the resin housing portion 81. However, after the covering body 7 is inserted into the resin housing portion 81 to form a cylindrical shape, the resin material J may be inserted into the interior of the covering body 7 wound in a cylindrical shape within the resin housing portion 81, and the resin material J may be accommodated in the resin housing portion 81. With this configuration, it is possible to reduce the adhesion of resin powder (resin scraps) to the resin housing portion 81.

[0092] Also, when the resin material J is accommodated after the covering body 7 is inserted into the resin housing portion 81, the covering body 7 within the resin housing portion 81 may prevent the insertion of the resin material J. To solve this problem, it is conceivable to provide a guide mechanism that presses the covering body 7 within the resin housing portion 81 against the inner surface of the resin housing portion 81 to guide the insertion of the resin material J.

[0093] Furthermore, the fixing portion 831 of the above-described embodiment is configured to adsorb the covering body 7 and fix it to the upper surface of the covering body winding jig, but it may also be configured to press and fix the covering body 7 to the upper surface of the covering body winding jig.

[0094] Moreover, the slit-shaped opening 82 may be connected to the upper portion of the resin housing portion 81, or may be at a position where the covering body 7 can be inserted into the resin housing portion 81. For example, it may be configured to be connected to the side portion or the lower portion of the resin housing portion 81.

[0095] In the above-described embodiment, the pot was formed in the lower mold and the cavity was formed in the upper mold. However, the pot or the cavity may be formed in any of the molds.

[0096] Also, the pot and the plunger are not limited to those having a circular cross-sectional shape. For example, they may have other shapes such as a rectangular cross-sectional shape or other polygonal cross-sectional shapes.

[0097] Furthermore, although the resin material transfer mechanism of the above-described embodiment was divided into three parts: a first transfer part, a second transfer part, and a transfer storage part, it may be configured with one transfer part for the first transfer part and the second transfer part, or it may be configured with one transfer part for the second transfer part and the transfer storage part. Also, it may be configured to transfer the resin material from the covering body winding mechanism to the pot by one transfer part.

[0098] Moreover, the resin molding apparatus is not limited to the multi-plunger method and may have one plunger. In this case, the plunger unit has a configuration with one plunger.

[0099] In addition, the pair of molding dies is not limited to the upper die and the lower die, and may be other molding dies (for example, a top gate type molding die having an intermediate plate) that can be used for transfer molding.

[0100] Needless to say, the present invention is not limited to the above-described embodiment, and various modifications are possible without departing from the spirit thereof.

Explanation of Reference Numerals

[0101] 100 ··· Resin molding apparatus J ··· Resin material P ··· Resin molded product 10 ··· Resin molding mechanism 21 ··· Pot 2 ··· Molding die (lower die) 32 ··· Cal part 33 ··· Runner part 7 ··· Covering body 8 ··· Covering body winding mechanism 81 ··· Resin storage part 81a ··· Relief part 81x ··· Guide surface 82 ··· Opening 83 ··· Feeding mechanism 831 ··· Fixed part 832 ··· Cutting part 833 ··· Insertion side roller 834 ··· Winding part side roller 84 ··· Push part 9 ··· Resin material conveying mechanism

Claims

1. A coating winding mechanism for winding a coating around the outer circumferential surface of a columnar resin material, and a resin molding mechanism for resin-molding using the resin material with the coating wound thereon. The coating winding mechanism includes a resin storage portion for storing the resin material, and a feeding mechanism for feeding the coating to the resin storage portion. A resin molding apparatus.

2. The coating winding mechanism has a slit-shaped opening communicating with the resin storage portion. The feeding mechanism feeds the coating from the opening into the resin storage portion. The resin molding apparatus according to claim 1.

3. The feeding mechanism has a fixing portion for fixing the coating outside the resin storage portion, and a cutting portion for cutting the coating fixed by the fixing portion. The resin molding apparatus according to claim 1 or 2, which feeds the coating cut by the cutting portion into the resin storage portion.

4. The coating is in the form of a sheet. The width dimension of the coating is a dimension capable of covering the entire axial direction of the outer circumferential surface of the resin material. The length dimension of the coating cut by the cutting portion is a dimension capable of winding the outer circumferential surface of the resin material one or more times. The resin molding apparatus according to claim 3.

5. The feeding mechanism has a roller for feeding the coating. The resin molding apparatus according to any one of claims 1 to 4.

6. The feeding mechanism has two rollers provided apart along a predetermined feeding direction for feeding the coating. The fixing portion and the cutting portion are provided between the two rollers. The resin molding apparatus according to claim 3 or 4.

7. A resin material conveying mechanism for conveying the resin material with the coating wound thereon to the resin molding mechanism. The resin molding apparatus according to any one of claims 1 to 6.

8. The coating winding mechanism has a push portion for extruding and delivering the resin material with the coating wound thereon to the resin material conveying mechanism. In the resin storage portion, a relief portion is formed to avoid interference with the push portion. The resin molding apparatus according to claim 7.

9. On the inner surface of the relief portion, a guide surface for guiding the coating with respect to the traveling direction of the coating is formed. The resin molding apparatus according to claim 8.

10. A method for manufacturing a resin molded product using the resin molding apparatus according to any one of claims 1 to 9.

Images