CN111941731A

CN111941731A - Resin molded article and method for producing resin molded article

Info

Publication number: CN111941731A
Application number: CN202010211449.8A
Authority: CN
Inventors: 池照弘树
Original assignee: Fuji Electric Co Ltd
Current assignee: Fuji Electric Co Ltd
Priority date: 2019-05-14
Filing date: 2020-03-24
Publication date: 2020-11-17
Anticipated expiration: 2040-03-24
Also published as: CN111941731B; JP7314612B2; JP2020185721A

Abstract

The invention provides a method for manufacturing a resin forming object, which comprises the following steps: a step of forming a resin molded article having a main body portion, a slit portion connected to the main body portion, and a mold release portion connected to the slit portion and having a thickness larger than that of the slit portion; and a step of removing the mold release portion from the resin molded product by applying an external force to the mold release portion. The resin molded article may further have a metal portion in contact with the main body portion, and the mold release portion may be provided to cover at least a part of the metal portion. The step of removing the mold release portion may be a step of exposing at least a part of the metal portion by removing the mold release portion from the resin molded product.

Description

Resin molded article and method for producing resin molded article

Technical Field

The present invention relates to a resin molded article and a method for producing the resin molded article.

Background

Conventionally, a method of filling a mold with a resin to mold a resin package is known. (see, for example, patent document 1).

Patent document 1: japanese patent No. 5706128

Disclosure of Invention

Technical problem to be solved by the invention

In the case of molding a resin package with a mold, it is preferable to suppress the occurrence of resin burrs.

Technical scheme for solving technical problem

The first aspect of the present invention provides a method for producing a resin molded article. The method for producing a resin molded article includes: a step of forming a resin molded article having a main body portion, a slit portion connected to the main body portion, and a mold release portion connected to the slit portion and having a thickness larger than that of the slit portion; and a step of removing the mold release portion from the resin molded product by applying an external force to the mold release portion.

The resin molded article may further have a metal portion in contact with the main body portion. The stripping section may be provided to cover at least a part of the metal portion. The step of removing the mold release portion may be a step of exposing at least a part of the metal portion by removing the mold release portion from the resin molded product.

The metal part may protrude from the main body part to the outside of the main body part.

The ejector may have a 1 st portion provided on an upper surface of the metal portion, and a 2 nd portion protruding from the 1 st portion in a direction parallel to the upper surface.

The demolding portion may be provided on a surface of the metal portion. The ejector may have an extension and a projection above the surface of the metal portion. The thickness of the convex portion may be larger than the thickness of the extended portion in a direction orthogonal to the surface of the metal portion.

The mold release portion may extend above an opening portion provided inside the main body portion.

A second aspect of the present invention provides a molded resin article. The resin molded article includes a main body portion and a slit portion connected to the main body portion. The fracture part has a plurality of surfaces. At least one surface of the fracture part is a fracture surface having a larger unevenness than the other surfaces.

The resin molded article may further have a metal portion in contact with the main body portion. A fracture surface may be provided above the metal portion.

In addition, the summary of the invention described above does not list all the necessary features of the present invention. In addition, sub-combinations of these feature groups may also constitute the invention.

Drawings

Fig. 1 is a diagram showing an example of the upper surface of a resin molded product 100 according to an embodiment of the present invention.

Fig. 2 is a diagram showing an example of the upper surface of the resin molded product 100 according to the embodiment of the present invention.

Fig. 3 is a view showing an example of a section a-a' in fig. 1.

Fig. 4 is a diagram showing an example of a cross section of a mold 80 according to an embodiment of the present invention.

Fig. 5 is a diagram showing an example of a method for producing a resin molded product 200 according to an embodiment of the present invention.

Fig. 6 is a diagram showing a method for producing a resin molded article 300 of a comparative example.

Fig. 7 is a diagram showing another example of the upper surface of the resin molded product 100 according to the embodiment of the present invention.

Fig. 8 is a view showing an example of a section c-c' in fig. 7.

Fig. 9 is a diagram showing an example of the upper surface of a resin molded product 200 according to an embodiment of the present invention.

Fig. 10 is a view showing an example of a section d-d' in fig. 9.

Fig. 11 is an enlarged view of the area a of fig. 10.

Detailed Description

The present invention will be described below with reference to embodiments thereof, but the following embodiments do not limit the invention according to the scope of the claims. In addition, the combination of the features described in the embodiments is not all necessary for the technical means to solve the technical problems of the present invention.

Fig. 1 is a diagram showing an example of the upper surface of a resin molded product 100 according to an embodiment of the present invention. The resin molded product 100 is formed by a step of forming a resin molded product among a plurality of steps of a method of manufacturing a resin molded product according to an embodiment of the present invention described later.

The resin molded product 100 includes a main body portion 10, a slit portion 20, and a mold release portion 30. The main body portion 10 is a main body of the resin molded product 100 and a resin molded product 200 (described later). The main body 10 is provided with a chip such as a pressure sensor unit as described later.

The tear portion 20 is connected to the main body 10. The demolding part 30 is connected to the fracture part 20. As described later, the main body 10, the slit part 20, and the mold releasing part 30 are integrally molded. As described later, the thickness of the fracture portion 20 is smaller than that of the mold release portion 30. Therefore, the durability of the fracture part 20 against the external force F is smaller than that of the mold release part 30 against the external force F. Thus, when an external force F is applied to the releasing portion 30, the fracture portion 20 is broken, and the releasing portion 30 is easily removed from the main body 10. In fig. 1, the broken portion 20 is indicated by thin hatching, and the mold release portion 30 is indicated by thick hatching.

The resin molded article 100 may be formed of a thermosetting resin that can be formed by injection molding. The resin may contain, for example, 1 or more kinds of polymer materials selected from polyphenylene sulfide (PPS) resin, polybutylene terephthalate (PBT) resin, Polyamide (PA) resin, acrylonitrile-butadiene-styrene (ABS) resin, Epoxy (EP) resin, Phenol Formaldehyde (PF) resin, and acrylic resin.

In this specification, technical matters will be described using orthogonal coordinate axes of X, Y, and Z axes. In the present specification, a plane parallel to the upper surface 12 of the main body 10 is an XY plane, and a depth direction of the main body 10 (a direction perpendicular to the upper surface 12) is a Z axis.

In the present specification, the side of upper surface 12 in the direction parallel to the depth direction of main body 10 is referred to as "upper", and the opposite side of upper surface 12 is referred to as "lower". In this example, the Z-axis direction is taken as the direction of gravity, but the "up" and "down" directions are not limited to the direction of gravity. The "up" and "down" directions are not limited to mounting directions to a substrate or the like when mounting the semiconductor device. For example, when the resin molded product 100 and the XYZ axes are rotated by 90 ° from the Z axis to the X axis around the Y axis, the plane parallel to the upper surface 12 is the YZ plane, and the X axis direction is the gravity direction. In this case, the side of upper surface 12 may be referred to as "upper", the opposite side of upper surface 12 may be referred to as "lower", and the depth direction of main body 10 (the direction perpendicular to upper surface 12, i.e., the horizontal direction) may be referred to as the Z axis. In the present specification, a plan view refers to a view from the upper surface 12 to the bottom surface 18 (described later) in the Z-axis direction.

The main body 10 of this example has two side walls 72 that face the X-axis direction and extend in the Y-axis direction, and two side walls 74 that face the Y-axis direction and extend in the X-axis direction. The two side walls 72 each have a predetermined thickness in the X-axis direction. The two side walls 74 each have a predetermined thickness in the Y-axis direction. The body portion 10 of this example has an outer surface 16. The outer surface 16 is an interface between the body 10 and the outside of the body 10. In fig. 1, the outer surface 16 in a plan view is indicated by a thick-line frame. In this example, the outer surface 16 is square in plan view.

The slit part 20-1 and the mold release part 30-1 of the present example are disposed outside the main body 10. The slit part 20-2 and the mold release part 30-2 of this example are disposed inside the main body 10. The fracture portion 20-1 and the mold release portion 30-1 of this example extend in the Y-axis direction. In the X-axis direction, one end of the slit part 20-1 is connected to the side wall 72 (outer surface 16), and the other end is connected to the mold release part 30-1. In this example, the mold release portion 30-1 is not connected to the side wall 72 (outer surface 16). In the X-axis direction, one end of the slit part 20-2 is connected to the side wall 72 (inner side surface 14), and the other end is connected to the mold release part 30-2. In this example, the mold release portion 30-2 is not connected to the side wall 72 (inner surface 14). In this example, the interface between the side wall 72 and the slit part 20 is a YZ plane.

The resin molded article 100 may further include a metal portion 40 in contact with the main body portion 10. The resin molded article 100 may have a plurality of metal portions 40. The resin molded product 100 of this example has 3 metal portions 40 overlapping with one side wall 72 in a plan view, and has 3 metal portions 40 overlapping with the other side wall 72. The metal part 40 may be a plate-like metal member having a longitudinal direction in the X-axis direction and a plane parallel to the XY-plane. The metal portion 40 is, for example, a lead frame. The metal portion 40 is formed of, for example, a metal containing Cu (copper).

The metal part 40 of this example projects outward from the inside of the body 10. The metal portion 40 of this example penetrates the side wall 72 in the X-axis direction. In addition, in this example, a part of the metal part 40 is provided below the upper surface 12, the slit part 20, and the mold release part 30. In fig. 1, the portion of the metal portion 40 that is not visible in a plan view is indicated by a broken line.

The breaking portion 20 and the ejector 30 may be provided to cover at least a part of the metal portion 40. The breaking portion 20-1 and the demolding portion 30-1 may be provided to cover at least a portion of each of the plurality of metal portions 40. In this example, the fracture portion 20-1 and the mold release portion 30-1 extending in the Y-axis direction are provided so as to cover at least a part of each of the 3 metal portions 40. The breaking portion 20-2 and the demolding portion 30-2 may be provided to cover at least a part of one metal portion 40.

The body portion 10 may have a 1 st recess 50 surrounded by sidewalls 72 and 74. The 1 st recess 50 has a predetermined depth from the upper surface 12 in the Z-axis direction. The bottom surface 17 is the bottom surface of the 1 st recess 50. The inner surface 14 is a side surface of the 1 st recess 50, and is an inner surface of the side wall 72 and the side wall 74. In addition, in this example, a part of the metal part 40 is placed on the bottom surface 17.

The main body 10 may further include a 2 nd recessed portion 60 inside the 1 st recessed portion 50 in a plan view. The 2 nd concave portion 60 has a predetermined depth from the bottom surface 17 in the Z-axis direction. The bottom surface 18 is the bottom surface of the 2 nd recess 60. The 2 nd recess 60 has an edge 62 at the position of the bottom surface 17 in the Z-axis direction. The edge 62 in this example is rectangular in plan view. In fig. 1, an edge 62 of the 2 nd recessed portion 60 disposed below the mold release portion 30-2 in a plan view is indicated by a broken line.

The inside of the body 10 may be provided with an opening 70. The opening 70 of this example is provided in the bottom surface 18 of the 2 nd recess 60. The opening 70 may penetrate the bottom surface 18. The opening 70 of this example is circular in plan view.

The 2 nd recess 60 has a chip such as a pressure sensor unit placed therein. The chip may be placed over the opening 70. The chip may be provided so as to cover the opening 70 in a plan view. As described later, the chip is bonded to the metal portion 40 through a metal wire inside the main body portion 10. In addition, the illustration of the lead and the chip is omitted in fig. 1.

The demolding portion 30-2 may extend to above the 2 nd concave portion 60 in the X-axis direction. The mold release part 30-2 may extend above the opening 70 in the X-axis direction. In other words, a part of the mold release part 30-2 may overlap a part of the opening 70 in a plan view. By extending the mold release portion 30-2 above the opening 70, as will be described later, the external force F in the direction from the bottom surface 18 toward the upper surface 12 is easily applied to the mold release portion 30-2 in the Z-axis direction.

In the present specification, the application direction of the external force F is not limited to the case where the application direction of the external force F is parallel to the Z-axis direction, and includes the case where the component of the application direction of the external force F in the Z-axis direction is larger than the component parallel to the XY plane. That is, the fact that the direction in which the external force F is applied is the Z-axis direction means a state in which the angle formed between the direction in which the external force F is applied and the Z-axis direction is less than 45 degrees.

As described above, when the external force F is applied to the mold releasing portion 30, the durability of the fracture portion 20 against the external force F is smaller than the durability of the mold releasing portion 30 against the external force F, and therefore, the fracture portion 20 is more likely to be broken than the mold releasing portion 30. When the fracture portion 20 is broken, the mold release portion 30 is removed from the main body portion 10. When the mold release part 30 is removed from the body part 10, the upper surface of the metal part 40 is exposed. In fig. 1, the direction of the external force F is indicated by a double circle mark. The external force F of this example is applied in the Z-axis direction in a direction from the bottom surface 18 toward the upper surface 12.

Fig. 2 is a diagram showing an example of the upper surface of the resin molded product 100 according to the embodiment of the present invention. Fig. 2 shows the 1 st portion 32 and the 2 nd portion 34 of the mold release portion 30 in the plan view of the resin molded article 100 of fig. 1. In fig. 2, the hatching of the slit part 20 and the mold release part 30 and the broken line of the edge 62 and the opening 70, which are illustrated in fig. 1, are omitted.

The ejector 30 of this example has a 1 st portion 32 provided on the upper surface of the metal portion 40, and a 2 nd portion 34 protruding from the metal portion 40. The 2 nd part 34 of this example protrudes from the metal part 40 in a direction parallel to the upper surface of the metal part 40. In fig. 2, the 1 st part 32 is a hatched part, and the 2 nd part 34 is an unshaded part. The 1 st part 32 and the 2 nd part 34 are integrally formed. The 2 nd portion 34 is a portion of the mold release portion 30 that does not overlap the metal portion 40 in a plan view. The 1 st part 32-1 and the 2 nd part 34-1 are disposed outside the main body 10. The 1 st part 32-2 and the 2 nd part 34-2 are disposed inside the main body portion 10.

The 2 nd portion 34-1 of this example projects in the Y-axis direction from the 1 st portion 32-1. The 2 nd portion 34-2 of this example projects in the X-axis direction from the 1 st portion 32-2. In the X-axis direction, the 2 nd portion 34-2 of this example protrudes from the 1 st portion 32-2 in the direction of the opening 70. Since the mold release portion 30 of this example has the 2 nd portion 34 protruding from the 1 st portion 32, the external force F is easily applied to the 2 nd portion 34 of the mold release portion 30 in the Z-axis direction along the direction from the bottom surface 18 toward the upper surface 12.

Fig. 3 is a view showing an example of a section a-a' in fig. 1. The section a-a' is an XZ plane passing through the body 10, the bottom 17, the bottom 18, the opening 70, the slit 20, the mold release 30, and the metal part 40. The side surface 19 is a side surface of the 2 nd recess 60.

The fracture part 20-1 of this example is sandwiched between the outer surface 16 and the mold release part 30-1 in the X-axis direction. The tear portion 20-1 may contact the outer side surface 16 and the mold release portion 30-1, respectively, in the X-axis direction. In this example, the mold release portion 30-1 does not contact the outer surface 16. The slit part 20-2 of this example is sandwiched between the inner surface 14 and the mold release part 30-2 in the X-axis direction. The tear portion 20-2 may contact the inner side 14 and the mold release portion 30-2, respectively, in the X-axis direction. In this example, the mold release portion 30-2 does not contact the inner surface 14.

A portion of the bottom surface of metal portion 40 may rest on bottom surface 17. The breaking portion 20 may be disposed in contact with an upper surface of the metal part 40. The mold release part 30 may be disposed in contact with an upper surface of the metal part 40.

The widths of the fracture part 20-2 and the mold release part 30-2 in the X-axis direction are set to a width W1 and a width W2, respectively. The width from the end of the mold release portion 30-2 on the inner surface 14 side to the side surface 19 in the X-axis direction is defined as a width W3. Width W2 may be greater than width W3. Width W1 is less than width W2. As described later, the releasing portion 30-2 is removed from the main body portion 10 by breaking the slit portion 20-2. Therefore, the smaller the width W1 is than the width W2, the more easily the fracture portion 20-2 is broken. When the mold release part 30-2 is removed, the upper surface of the metal part 40 contacting the lower surface of the mold release part 30-2 is exposed. Therefore, as the width W2 increases, a metal wire (described later) can be more easily bonded to the upper surface of the metal portion 40.

The width W2 may be 5 times or more the width W1, or 10 times or more the width W1. The width W2 may be 1.2 times or more the width W3, or 1.5 times or more the width W3. The width W1 may be 1 μm or more and 200 μm or less. The width W1 is, for example, 100 μm. The width W2 may be 0.5mm or more and 10mm or less. The width W2 is, for example, 5 mm.

The thickness of the fracture part 20 and the thickness of the mold release part 30 above the metal part 40 are set to t1 and t2, respectively. Thickness t1 and thickness t2 are the thicknesses of the fracture part 20 and the mold release part 30, respectively, in the direction perpendicular to the upper surface of the metal part 40 (Z-axis direction).

Thickness t2 is greater than thickness t 1. The thickness t2 may be 5 times or more the thickness t1, or 10 times or more the thickness t. The thickness t1 may be 1 μm or more and 200 μm or less. The thickness t1 is, for example, 100 μm. The thickness t2 may be 20 μm or more, 250 μm or more, or 500 μm or more.

In this example, the width W1 of the fracture 20-2 is smaller than the width W2 of the mold release 30-2, and the thickness t1 of the fracture 20-2 is smaller than the thickness t2 of the mold release 30-2. Therefore, the durability of the fracture part 20-2 against the external force F is smaller than that of the mold release part 30-2. Therefore, when the external force F is applied to the mold releasing portion 30-2, the mold releasing portion 30-2 is easily removed from the main body portion 10 from the slit portion 20-2. In fig. 3, the direction of the external force F is indicated by a dashed-dotted arrow.

The mold release part 30-2 may extend above the opening 70 in the X-axis direction. By extending the mold release portion 30-2 above the opening 70, the external force F can be applied to the mold release portion 30-2 from below the body 10 through the opening 70 and the 2 nd recessed portion 60. Therefore, the external force F is easily applied to the mold release portion 30-2 in the Z-axis direction along the direction from the bottom surface 18 toward the upper surface 12.

Similarly, in this example, the durability of the fracture part 20-1 against the external force F is smaller than the durability of the mold release part 30-1 against the external force F. Therefore, when the external force F is applied to the mold releasing portion 30-1, the mold releasing portion 30-1 is easily removed from the main body portion 10 from the slit portion 20-1. In fig. 3, the direction of the external force F is indicated by a broken-line arrow.

Fig. 4 is a diagram showing an example of a cross section of a mold 80 according to an embodiment of the present invention. The mold 80 is a mold for forming the resin molded article 100. Fig. 4 shows an example of an XZ cross section of the mold 80. Before the resin molded product 100 is formed, the mold 80 may be separated into a mold 80-1 and a mold 80-2. In this example, in the step of forming the resin molded article 100, the mold 80-1 and the mold 80-2 are integrated with each other by sandwiching the metal part 40 between the mold 80-1 and the mold 80-2.

The mold 80 has a space 84 therein corresponding to the shape of the resin molded product 100. The spaces 84-3 and 84-4 correspond to the shape of the seam breaks 20-1 and 20-2, respectively. The space 84-5 and the space 84-6 correspond to the shapes of the ejector 30-1 and the ejector 30-2, respectively.

The mold 80 has an opening 82 for allowing resin to flow therein. The opening 82 connects the exterior of the mold 80 and the space 84. The space 84 communicates with the outside of the mold 80 through the opening 82. The resin flowing in from the opening 82 is filled in the space 84.

Fig. 5 is a diagram showing an example of a method for producing a resin molded product 200 according to an embodiment of the present invention. The method of manufacturing the resin molded product 200 includes the steps of forming the resin molded product 100 (steps S100 to S104) and removing the mold release portion 30 from the resin molded product 100 (step S106). The method for producing the resin molded product 200 of this example includes three steps of step S100, step S102, and step S104 as steps for forming the resin molded product 100.

In the method of manufacturing the resin molded product 200 of this example, in step S100, the liquid resin is filled into the space 84 from the opening 82 of the mold 80. The resin of this example is a thermosetting resin that can be injection molded. The resin may contain, for example, 1 or more kinds of polymer materials selected from polyphenylene sulfide (PPS) resin, polybutylene terephthalate (PBT) resin, Polyamide (PA) resin, acrylonitrile-butadiene-styrene (ABS) resin, Epoxy (EP) resin, Phenol Formaldehyde (PF) resin, acrylic resin, and the like. In step S100 of this example, the space 84 is filled with a liquid resin by heating the resin.

In the method of manufacturing the molded resin product 200 of this example, the liquid resin 90 filled in the space 84 is cooled and solidified in step S102. In step S102, the hatching of the mold 80 shown in step S100 is omitted, and the resin 90 is indicated by hatching.

In the method of manufacturing the resin molded product 200 of this example, in step S104, the mold 80 is removed from the cured resin 90. In step S104, the resin molded product 100 in which the main body portion 10, the slit portion 20, and the mold release portion 30 are integrally molded is produced. In addition, in step S104, the metal portion 40 is also integrated with the resin molded article 100. Further, the shading of the resin 90 shown in step S102 is omitted in step S104.

In the method of manufacturing the resin molded product 200 of this example, in step S106, an external force F in the Z-axis direction is applied to the mold releasing portion 30, and the mold releasing portion 30 is removed from the main body portion 10. In this example, the external force F is applied to the mold releasing portion 30 to break the slit portion 20, thereby removing the mold releasing portion 30 from the main body portion 10.

Step S106 may be a step of exposing at least a part of the metal part 40 by removing the mold release part 30 from the resin molded article 100. By removing the mold release part 30 from the main body 10, the mold release part 30 contacting the upper surface of the metal part 40 is peeled off, and a part of the metal part 40 is exposed. In step S106, the resin molded product 200 is produced. The resin molded product 200 is a final product of the resin molded product produced by the method for producing the resin molded product 200 of the present embodiment. In step S106 of fig. 5, the resin molded product 200 is indicated by hatching.

The method for producing the resin molded article 200 may further include step S108. Step S108 is a step of placing chip 130 on 2 nd concave portion 60 of resin molded product 200. Chip 130 may be placed on bottom surface 18. The chip 130 may be placed so as to cover the opening 70 (see fig. 1 and 2) in a plan view. The chip 130 is, for example, a pressure sensor unit.

Step S108 may further include the step of bonding the chip 130 and the upper surface of the metal part 40 with the wire 140. The conductive line 140 may be formed of metal. The wire 140 is formed of Al (aluminum), for example.

In the method for producing the resin molded product 200 of the present example, in steps S100 to S104, the resin molded product 200 is formed such that the thickness of the resin in the portion of the upper surface of the metal part 40 where the resin 90 may remain is smaller than the thickness of the resin in the portion where the resin 90 is to be reliably removed. In this example, the portion of the upper surface of the metal portion 40 from which the resin 90 is to be reliably removed is a portion to which the lead wire 140 is bonded after the resin 90 is removed. In the method for producing the resin molded product 200 of the present example, in steps S100 to S104, the resin molded product 200 is formed so that the mold release part 30 is disposed above the portion of the upper surface of the metal part 40 from which the resin 90 is to be reliably removed, and the slit part 20 is disposed above the portion of the upper surface from which the resin 90 may remain.

In the method for producing the resin molded product 200 of the present example, in the next step S106, an external force F is applied to the mold releasing portion 30, and the mold releasing portion 30 is removed from the main body portion 10. Since the durability of the broken portion 20 against the external force F is smaller than the durability of the mold releasing portion 30 against the external force F, the broken portion 20 is more likely to be broken than the mold releasing portion 30 when the external force F is applied to the mold releasing portion 30. In the case where the mold release part 30 is removed in this way, the resin 90 is less likely to remain on the upper surface of the metal part 40 in contact with the lower surface of the mold release part 30. By removing the mold release part 30 in this way, the method of manufacturing the molded resin product 200 of the present embodiment can reliably remove the resin 90 at the portion where the lead wire 140 is joined. Therefore, in the next step S108, the bonding of the upper surface of the metal part 40 and the wire 140 becomes easy.

Fig. 6 is a diagram showing a method for producing a resin molded article 300 of a comparative example. The method for manufacturing the resin molded article 300 of the comparative example includes the step S200 of filling the mold 180 with the resin, the step S202 of cooling and solidifying the resin filled in the mold 180, and the step S204 of removing the mold 180 from the solidified resin 90.

The mold 180 has a space 184-1 and a space 184-2 corresponding to the shape of the resin molded article 300. The mold 180 does not have a space 84-3 for forming the slit part 20-1, a space 84-4 for forming the slit part 20-2, a space 84-5 for forming the mold release part 30-1, and a space 84-6 for forming the mold release part 30-2. The mold 180 differs in these respects from the mold 80 shown in fig. 4.

In the diagram of step S200, the metal portion 42 to be bonded with the wire after that is shown in black. The metal portion 42 is a part of the metal portion 40, and is simply indicated by black for convenience of description.

Mold 180-1 is designed such that mold 180-1 contacts the upper surface of metal part 42 so that resin does not enter above metal part 42. However, due to design errors, a space 184-3 having a slight thickness is sometimes generated above the metal portion 42. If space 184-3 is present above metal portion 42, resin 90 may enter space 184-3 if resin is filled from opening 182 in step S202.

In the present comparative example, the mold 180-1 is disposed above and the mold 180-2 is disposed below, respectively, but the mold 180-2 may be disposed above and the mold 180-1 may be disposed below, respectively. In this case, a space 184-3 having a minute thickness is sometimes generated below the metal part 42 due to a design error. Even when there is the space 184-3 below the metal portion 42, the resin 90 may enter the space 184-3 when the opening 182 is filled with the resin in step S202.

In the present comparative example, the Z-axis direction is taken as the gravity direction, and therefore the upper surface of the metal portion 42 is a horizontal surface (parallel to the XY plane). When the mold 180 and the XYZ axes are rotated by 90 ° from the Z axis to the X axis around the Y axis, the X axis direction is the gravity direction, and the upper surface of the metal portion 42 is a vertical surface (parallel to the XY surface). Even in this case, if the opening 182 is filled with the resin in step S202, the resin 90 may enter the space 184-3 adjacent to the metal portion 42 in the horizontal direction (Z-axis direction).

When the resin 90 enters the space 184-3 in step S202, if the mold 180 is removed from the resin 90 in step S204, a part of the resin 90 that enters the upper surface of the metal part 42 is not removed and easily remains. Fig. 6 schematically shows a rectangular quadrangle of the resin 90 (which may be called a burr). According to the method of manufacturing the resin molded article 300 of the comparative example, the resin 90 is likely to remain on a part of the upper surface of the metal portion 42. When the residual resin 90 is removed by cleaning with high-pressure water such as air blowing (blast), it is difficult to obtain the resin 90 in the same manner if the pressure is low, and the metal part 40 and a part of the main body 10 around the metal part 40 are easily damaged if the pressure is high. In addition, when the residual resin 90 is removed by laser irradiation, the metal portion 40 and a part of the main body portion 10 around the metal portion 40 are easily damaged.

Fig. 7 is a diagram showing another example of the upper surface of the resin molded product 100 according to the embodiment of the present invention. The resin molded product 100 of this example differs from the resin molded product 100 shown in fig. 1 in that the mold release part 30-1 has the extended part 35 and the convex part 36, and the mold release part 30-2 has the extended part 37 and the convex part 38. In this example, the main body 10, the slit part 20, and the mold releasing part 30 are also integrally molded. The

projections

36 and 38 protrude more than the upper surface of the extension 35 and the upper surface of the extension 37, respectively, as described later.

In the X-axis direction, the end of the extending portion 35 on the outer surface 16 side is connected to the slit portion 20-1, and the end of the extending portion 35 opposite to the end is connected to the convex portion 36. In the X-axis direction, the end portion of the extending portion 37 on the inner surface 14 side is connected to the slit portion 20-2, and the end portion of the extending portion 35 on the opening portion 70 side is connected to the projection 38.

The position of the end of the convex portion 38 on the opening 70 side may be equal to the position of the end of the metal portion 40 on the opening 70 side in the X-axis direction, or may be equal to the position of the edge 62 of the 2 nd concave portion 60. That is, in the X-axis direction, the end position of the convex portion 38 on the opening 70 side, the end position of the metal portion 40 on the opening 70 side, and the position of the edge 62 of the 2 nd concave portion 60 may coincide with each other in a plan view. The end position of the convex portion 38 on the opening 70 side may be arranged closer to the inner surface 14 side than the end position of the metal portion 40 on the opening 70 side in the X-axis direction.

When the mold release portion 30-1 of this example is removed from the main body portion 10, an external force F is applied to an end surface (YZ surface) of the convex portion 36 opposite to the outer side surface 16 in the X-axis direction in a direction from the outside toward the inside of the main body portion 10 in the X-axis direction. In fig. 7, the direction of the external force F is indicated by a dashed-dotted arrow. When the mold release portion 30-2 of this example is removed from the main body portion 10, an external force F is applied to an end surface (YZ surface) of the convex portion 38 on the opening 70 side in the X-axis direction in a direction from the inside toward the outside of the main body portion 10 in the X-axis direction. In fig. 7, the direction of the external force F is indicated by a broken-line arrow.

In the present specification, the case where the direction of application of the external force F is the X-axis direction is not limited to the case where the direction of application of the external force F is parallel to the X-axis direction, and includes the case where the component of the direction of application of the external force F in the X-axis direction is larger than the component parallel to the YZ plane. That is, the direction in which the external force F is applied is the X-axis direction, which means a state in which the angle formed between the direction in which the external force F is applied and the X-axis direction is less than 45 degrees.

Fig. 8 is a view showing an example of a section c-c' in fig. 7. The resin molded product 100 of this example differs from the resin molded product 100 shown in fig. 3 in that the mold release part 30-1 has the extended part 35 and the convex part 36, and the mold release part 30-2 has the extended part 37 and the convex part 38. In fig. 8, the extending portion 35 and the protruding portion 36 are shown as having boundaries for convenience, but may be integrally molded as an integral mold release portion 30-1. The same applies to the extension 37 and the projection 38.

The mold release part 30-1 has an extension 35 and a protrusion 36 above the metal part 40. The bottom surface of the extension portion 35 and the bottom surface of the projection portion 36 contact the upper surface of the metal portion 40 outside the main body portion 10. The end portion of the extended portion 35 on the outer surface 16 side is connected to the slit portion 20-1. The mold release part 30-2 has an extension 37 and a projection 38 above the metal part 40. The bottom surface of the extension portion 37 and the bottom surface of the projection 38 contact the upper surface of the metal portion 40 inside the main body portion 10. The end portion of the extended portion 37 on the side of the inner surface 14 is connected to the slit portion 20-2.

The

projections

36 and 38 protrude more than the upper surface of the extension 35 and the upper surface of the extension 37, respectively. In other words, the upper surface of convex portion 36 is disposed closer to upper surface 12 than the upper surface of extending portion 35, and the upper surface of convex portion 38 is disposed closer to upper surface 12 than the upper surface of extending portion 37.

The thickness (height) of the

convex portions

36 and 38 above the metal portion 40 is set to a thickness t 3. Thickness t3 is greater than thickness t 2. The thickness t3 may be 2 times or more the thickness t2, or 5 times or more the thickness t 2. The thickness t3 may be 250 μm or more, 500 μm or more, or 1000 μm or more.

In this example, when the mold release portion 30-2 is removed from the main body portion 10, the external force F is applied to a predetermined position of the convex portion 38 in the Z-axis direction in the X-axis direction and in a direction from the inner side toward the outer side of the main body portion 10. The predetermined position is a position between the upper surface of the extending portion 37 and the upper surface of the convex portion 38 in the Z-axis direction. In this example, since the thickness t3 of the projection 38 is larger than the thickness t2 of the extension 37, the external force F is applied as described above, and thus a rotational force in a direction approaching the inner side surface 14 is easily applied to the mold release part 30-2 centering on the slit part 20-2. Since the durability of the fractured portion 20-2 to the external force F is smaller than that of the mold release portion 30-2 to the external force F, if the external force F is applied to the convex portion 38 in the above direction, the fractured portion 20-2 is broken, and thus the mold release portion 30-2 is easily removed from the main body portion 10. In fig. 7, the direction of the external force F is indicated by a broken-line arrow.

The width of the mold release portion 30-2 in the X-axis direction in this example was set to be a width W2'. The width W2' may be equal to the width W3 or less than the width W3. That is, the mold release portion 30-2 of the present example may not protrude in a direction parallel to the upper surface of the metal portion 40 and in a direction from the metal portion 40 toward the opening 70. In this example, since the external force F is applied in the X-axis direction, even if the width W2' is equal to or smaller than the width W3 or the width W3, the mold release part 30-2 can be removed from the main body part 10.

The thickness t3 may be determined according to the width W2'. That is, the thickness t3 may be a predetermined thickness corresponding to the width W2'. The predetermined thickness may be a thickness that facilitates removal of the mold release portion 30-2 from the main body portion 10 by application of the external force F and that does not easily break only the convex portion 38. If the thickness t3 is smaller than the predetermined thickness, the external force F for removing the mold release part 30-2 from the main body 10 tends to increase. When the thickness t3 is larger than the predetermined thickness, only the convex portion 38 is easily broken by the application of the external force F. When only the convex portion 38 is broken, at least a part of the extension portion 37 is likely to remain on the upper surface of the metal portion 40. Therefore, the thickness t3 is preferably the predetermined thickness corresponding to the width W2'.

Similarly, in this example, when the mold release part 30-1 is removed from the main body 10, the external force F is applied to a predetermined position of the convex part 36 in the Z-axis direction in the X-axis direction and in a direction from the outer side to the inner side of the main body 10. The predetermined position is a position between the upper surface of the extended portion 35 and the upper surface of the convex portion 36 in the Z-axis direction. In this example, since the thickness t3 of the projection 36 is larger than the thickness t2 of the extension 35, the external force F is applied as described above, and thus a rotational force in a direction approaching the outer surface 16 is easily applied to the mold release part 30-1 around the fracture part 20-1. Since the durability of the fractured portion 20-1 to the external force F is smaller than that of the mold release portion 30-1 to the external force F, if the external force F is applied to the convex portion 36 in the above direction, the fractured portion 20-1 is broken, and thus the mold release portion 30-1 is easily removed from the main body portion 10. In fig. 7, the direction of the external force F is indicated by a dashed-dotted arrow.

Fig. 9 is a diagram showing an example of the upper surface of a resin molded product 200 according to an embodiment of the present invention. The resin molded product 200 is a final product of the resin molded product produced by the method for producing the resin molded product 200 according to the embodiment of the present invention (see fig. 5). That is, the resin molded product 200 is a resin molded product obtained by removing the mold release part 30 from the resin molded product 100 shown in fig. 1.

The resin molded product 200 has a main body portion 10 and a slit portion 22. The main body portion 10 is a main body of the resin molded product 200. The main body portion 10 may be provided with a chip such as a pressure sensor unit. The slit part 22-1 is disposed outside the main body part 10. The slit part 22-2 is disposed inside the body part 10.

The tear portion 22 is connected to the main body 10. The slit portion 22 of the present example is a part of the slit portion 20 remaining after the mold release portion 30 is removed from the main body portion 10 (see step S106 of fig. 5). In step S106 shown in fig. 5, the parting section 30 is removed from the main body section 10 by breaking the fracture section 20. Therefore, of the two ends of the slit portion 22 in the X-axis direction, the end surface on the side connected to the die-release portion 30 becomes a fracture surface. Therefore, the end face is less likely to be linear in a plan view. In fig. 9, the shape of the end surface in a plan view is shown by wavy lines.

The resin molded product 200 of this example further includes a metal portion 40. The metal part 40 may be a plate-like metal member having a longitudinal direction in the X-axis direction and a plane parallel to the XY-plane. In fig. 9, the metal portion 40 penetrates the side wall 72 and protrudes outward of the main body 10 in the X-axis direction. The metal portion 40 is, for example, a lead frame. The metal portion 40 is formed of, for example, a metal containing copper (Cu).

In the top view of fig. 9, the upper surface of the metal part 40 is exposed except for the portion overlapping the side wall 72 and the seam part 22. A metal wire is bonded to the upper surface of the exposed metal portion 40. The wire electrically connects the metal portion 40 with the chip placed in the 2 nd recess 60.

Fig. 10 is a view showing an example of a section d-d' in fig. 9. The d-d' cross section is an XZ plane passing through the body portion 10, the bottom surface 17, the bottom surface 18, the opening portion 70, the slit portion 22, and the metal portion 40.

In this example, a part of the metal part 40 is placed on the bottom surface 17 of the 1 st recess 50. The broken portion 22-1 remains in contact with the upper surface and the outer side surface 16 of the metal portion 40. The broken portion 22-2 remains in contact with the upper surface and the inner side surface 14 of the metal portion 40.

Fig. 11 is an enlarged view of the area a of fig. 10. The region a includes the tear portion 22-1, the metal portion 40, and the outer surface 16 of the main body 10. In fig. 11, an XZ cross section of a fracture surface of the fracture part 22-1 is schematically shown. In fig. 11, the broken portion 22-1 is indicated by thin hatching, and the metal portion 40 is indicated by thick hatching.

The tear-off portion 22 has a plurality of faces 24. The fracture part 22-1 of this example has four faces 24-1 to 24-4. At least one face 24 is a fracture face. In this example, the surface 24-1 is a fracture surface, and the surfaces 24-2 to 24-4 are not fracture surfaces. In FIG. 11, the shape of the XZ cross section of the fracture surface 24-1 is shown by a thick line. In this example, surface 24-3 contacts outer surface 16, and surface 24-4 contacts the upper surface of metal portion 40.

As described above, the slit portion 22 of the present example is a part of the slit portion 20 remaining after the mold release portion 30 is removed from the main body portion 10. The broken portion 20 is broken by an external force F (see fig. 1 and 3), and therefore the surface 24-1 after the breakage is likely to have an uneven shape having a plurality of surfaces in different directions. Here, the direction of the surface refers to a normal direction of the surface. That is, the surface 24-1 easily has a plurality of surfaces whose normal directions are different from each other. The slit part 22-1 of this example has four different directional surfaces 24-1 in the d-d' cross section.

The face 24-1 may have a plurality of recesses 26. The concave portion 26 is a part of the surface 24-1, and includes a portion where the distance between the surface 24-1 and the outer side surface 16 in the X-axis direction is extremely small. In this example, face 24-1 has 2 recesses 26-1 and 26-2.

The maximum width of the slit part 22-1 in the X-axis direction is defined as a width Wd 1. Width Wd1 is the width between the end position of surface 24-1 farthest from outer side surface 16 in the X-axis direction and outer side surface 16.

In the X-axis direction, the minimum value of the depth of the recess 26 is defined as a width Wd2, and the maximum value of the depth of the recess 26 is defined as a width Wd 3. When the surface 24-1 has three or more recesses 26, the minimum value of the depth of each of the three or more recesses 26 is defined as the width Wd2, and the maximum value is defined as the width Wd 3.

The size of the irregularities of the surface 24-1 is larger than the size of the irregularities of the surfaces 24-2 to 24-4. The size of the irregularities of the surface 24 may be an average value of the depth of the plurality of recesses 26 occupying the width Wd 1. In this example, the average depth of the plurality of concave portions 26 is ((Wd1+ Wd 2)/2). The size of the irregularities on the surface 24 may be a ratio of the minimum depth of the recessed portion 26 to the maximum depth of the recessed portion 26 (Wd 2/Wd3 in this example). The size of the irregularities of the surface 24 may be a ratio of the maximum value Wd3 of the depth of the concave portion 26 to the width Wd1 (i.e., Wd3/Wd1), or a ratio of the minimum value Wd2 of the depth of the concave portion 26 to the width Wd1 (i.e., Wd2/Wd 1). Since the surface 24-1 is a fracture surface, the size of the irregularities of the surface 24-1 is larger than the size of the irregularities of the surfaces 24-2 to 24-4 which are not fracture surfaces.

Face 24-1 may be disposed over metal portion 40. As shown in fig. 3, since the broken portion 20 and the mold releasing portion 30 are disposed above the metal portion, the broken portion 22 remaining after the mold releasing portion 30 is removed is disposed on the metal portion 40.

The present invention has been described above with reference to the embodiments, but the technical scope of the present invention is not limited to the scope described in the above embodiments. It will be apparent to those skilled in the art that various changes and modifications can be made in the above embodiments. It is clear from the description of the scope of the claims that the embodiment to which such a change or improvement is applied is also included in the technical scope of the present invention.

Note that the execution order of each process such as the operation, the process, the step, and the stage in the apparatus, the system, the program, and the method shown in the claims, the description, and the drawings can be realized in any order unless "before", and the like are explicitly indicated and an output of a previous process is not used in a subsequent process. The operational flow in the claims, the specification, and the drawings is described using "first", "next", and the like for convenience of description, but this does not necessarily mean that the operations are performed in this order.

Description of the reference symbols

10, 12, top, inner, outer, 17, bottom, 18, side, seam, 22, seam, 24, recess, 30, demolding, 32, 1, 2, extension, 36, projection, 37, extension, 38, projection, 40, metal, 42, 50, 1, 2, edge, 70, opening, 180, side, wall, opening, 180, opening, resin, 100, opening, resin, 100, opening, 180, opening, mold, wall, 24, opening, 180, opening, mold, wall, 180, opening, mold, wall, and opening, 30, 20, opening, 24, opening, wall, and opening, 30, opening, and opening, 182. opening part, 184. space, 200. resin molded article, and 300. resin molded article.

Claims

1. A method for producing a resin molded article, comprising:

forming a resin molded article having a main body portion, a slit portion connected to the main body portion, and a mold release portion connected to the slit portion and having a thickness larger than that of the slit portion; and

and removing the mold release portion from the resin molded product by applying an external force to the mold release portion.

2. The method for producing a resin molded article according to claim 1,

the resin molded product further has a metal portion in contact with the main body portion,

the stripper portion is arranged to cover at least a portion of the metal portion,

the step of removing the mold release portion is a step of exposing at least a part of the metal portion by removing the mold release portion from the resin molded product.

3. The method for producing a resin molded article according to claim 2,

the metal portion protrudes from the main body portion to an outside of the main body portion.

4. The method for producing a resin molded article according to claim 2 or 3,

the mold release part has:

a 1 st portion disposed on an upper surface of the metal portion; and

a 2 nd portion protruding from the metal portion in a direction parallel to the upper surface.

5. The method of producing a resin molded article according to any one of claims 2 to 4,

the demolding part is arranged on the surface of the metal part,

the mold release portion has an extension and a projection above the surface of the metal portion,

the thickness of the convex portion is larger than the thickness of the extended portion in a direction orthogonal to the surface.

6. The method of producing a resin molded article according to any one of claims 1 to 5,

the mold release portion extends above an opening provided inside the main body portion.

7. A resin molded article characterized by comprising:

a main body portion; and

a fracture part connected with the main body part,

the breaking seam portion has a plurality of faces,

at least one of the surfaces is a fracture surface having a larger unevenness than the other surfaces.

8. The resin molding according to claim 7,

further comprises a metal portion in contact with the main body portion,

the fracture surface is disposed above the metal portion.