Resin Molding Machine Radial Layout and Thermal Isolation
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Solution Overview
Problem
Conventional resin molding machines face challenges in efficiently performing sequential processes, such as feeding, molding, and accommodating semiconductor devices, while preventing adhesive sheet degradation and resin scattering, which affects product quality and handling efficiency.
Innovation Solution
A compact resin molding machine design featuring a work conveying mechanism with a rotating and linearly moving robot hand, a modular structure for processing sections, and a work supporting section that maintains the carrier plate away from the clamping face to control heat transfer, along with a windshield to shield resin powders during conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the carrier plate is placed directly on the clamping face for resin molding, then molding efficiency is improved, but heat conduction causes adhesive sheet degradation and resin viscosity increase
Solution Approach 1:
A work supporting section acts as an intermediary between the carrier plate and clamping face, using a release film to prevent direct heat conduction while enabling molding. The release film serves as a thermal barrier that protects the adhesive sheet from degradation caused by direct contact with the heated clamping face.
Solution Approach 2:
The system separates the carrier plate from the clamping face by introducing a release film layer, creating distinct functional zones: the carrier plate holds the work, the release film provides thermal isolation and release capability, and the clamping face applies pressure for molding without direct thermal contact.
2Ease of manufacture
If granular resin is fed directly onto the work, then resin application is simplified, but resin scattering occurs and cleanliness deteriorates
Solution Approach 1:
The release film serves as an intermediary surface for resin application. Granular resin is fed onto the release film rather than directly onto the work, allowing controlled resin distribution and preventing scattering. The release film contains the resin in a manageable state before transfer to the work.
Solution Approach 2:
The release film is prepared in advance as a resin receiving surface, allowing resin to be fed and distributed before the actual molding process. This preliminary resin application on the release film prevents scattering during subsequent handling and transfer operations.
3Device complexity
If multiple processing sections are arranged linearly, then process flow is simplified, but machine size increases and compactness is reduced
Solution Approach 1:
The processing sections are arranged in a radial configuration around the robot's moving area rather than in a linear sequence. This spatial reorganization allows multiple processing sections to be accessed efficiently by the robot without requiring linear arrangement, reducing the overall machine footprint while maintaining process flow simplicity.
Solution Approach 2:
The robot serves as a universal work conveying mechanism that can access and transfer works between multiple processing sections arranged radially. This multi-functional robot replaces the need for dedicated conveyance mechanisms between each linearly arranged section, compacting the overall machine structure.
4Ease of operation
If the robot moving area is left open for accessibility, then operation and maintenance are easier, but resin powders scatter during conveyance
Solution Approach 1:
A windshield is introduced specifically in the resin feeding area to provide localized protection against resin powder scattering. The windshield is positioned only where resin handling occurs, providing targeted containment without completely enclosing the robot moving area, thus maintaining accessibility while preventing harmful scattering in critical zones.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables efficient sequential processing, improves product quality by maintaining resin flowability, reduces maintenance costs, and prevents resin scattering, resulting in a more compact and efficient resin molding operation.
Implementation Method 1
a work supporting section that maintains the carrier plate away from the clamping face to control heat transfer
Implementation Method 2
along with a windshield to shield resin powders during conveyance
Data Source
AI summary
The compact resin molding machine is capable of efficiently performing a sequence of molding actions from feeding a work and resin to accommodating the molded work. The resin molding machine comprises: a work conveying mechanism including a robot, which has a robot hand for holding the work and which is capable of rotating and linearly moving; a work feeding section for feeding the work; a resin feeding section for feeding the resin; a press section including a molding die set, in which the work is resin-molded; a work accommodating section for accommodating the molded work; and a control section controlling the entire resin molding machine. The work feeding section, the resin feeding section, the press section and the work accommodating section are located to enclose a moving area of the robot of the work conveying mechanism.