INSPECTION METHOD, INSPECTION APPARATUS, PRODUCTION METHOD, AND PRODUCTION SYSTEM FOR HEATSINK

A method for inspecting a heatsink in which a heat dissipation layer is formed on a surface of a substrate formed by casting, includes shooting the heat dissipation layer by image pickup means in a state where residual heat transferred from the substrate to the heat dissipation layer remains and thereby acquiring image data representing a temperature distribution on a surface of the heat dissipation layer, the heat dissipation layer being formed by performing a film-forming process on the surface of the substrate where residual heat that is generated when the substrate is cast remains, the image pickup means being configured to receive an emission of light from molecules of the heat dissipation layer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from Japanese patent application No. 2018-2907, filed on Jan. 11, 2018, the disclosure of which is incorporated herein in its entirety by reference.

BACKGROUND

The present disclosure relates to an inspection method, an inspection apparatus, a production method, and a production system for a heatsink. For example, the present disclosure relates to an inspection method, an inspection apparatus, a production method, and a production system for a heatsink in which a heat dissipation layer is formed on a surface of a substrate which is formed by casting.

In recent years, for example, as sizes of electric circuits in semiconductor devices decrease, heat-generation densities of these electric circuits are increasing. Therefore, it is important to improve heat dissipation performance of such electric circuits and hence heatsinks are provided in such electric circuits. A substrate that constitutes such a heatsink is usually formed of a metal having a high thermal conductivity such as aluminum. However, although the thermal conductivity of the metal such as aluminum in itself is high, conductivity of heat from the metal to the air tends to be low. Therefore, a layer of carbon, a nitride, a resin, or the like that has a higher thermal conductivity to the air than the thermal conductivity from the metal to the air is formed as a heat dissipation layer on a surface of the substrate.

Incidentally, Japanese Unexamined Patent Application Publication No. S57-202683 discloses a method for manufacturing a heat dissipation base for an electro-thermal apparatus, in which a resin layer is formed on a surface of a substrate in a state where residual heat that is generated when the substrate is formed by casting remains.

Further, Japanese Unexamined Patent Application Publication No. 2003-139731 discloses a structure inspection/diagnosis system in which after a surface of a concrete structure is heated by heating means, the surface of the concrete structure is shot (i.e., photographed) by a thermography apparatus and the concrete structure is inspected for presence of cracking and the like based on acquired image data.

SUMMARY

The applicant of the present application has found the following problem. In the case where a heat dissipation layer is formed on a surface of a substrate of a heatsink, the following problem could occur. That is, the heat dissipation layer could be peeled off from the surface of the substrate due to a release agent adhering to the surface of the substrate and/or a temperature of the substrate at the time when the heat dissipation layer is formed. Therefore, for example, although it is possible to inspect the degree of peeling of the heat dissipation layer from the surface of the substrate by using the structure inspection/diagnosis system disclosed in Japanese Unexamined Patent Application Publication No. 2003-139731, it is necessary to inspect the degree of peeling of the heat dissipation layer from the surface of the substrate by using the thermography apparatus after heating the heat dissipation layer by using the heating means. Consequently, it takes time to reheat the heat dissipation layer. As a result, there is a problem that it takes time to inspect whether the heatsink is defective or not, thus making the inspection inefficient.

The present disclosure has been made in view of the above-described problem and an object thereof is to provide an inspection method, an inspection apparatus, a production method, and a production system for a heatsink, capable of improving efficiency of a process for inspecting whether a heatsink is defective or not based on a degree of peeling of a heat dissipation layer from a surface of a substrate.

A first exemplary aspect is a method for inspecting a heatsink in which a heat dissipation layer is formed on a surface of a substrate formed by casting, including

shooting the heat dissipation layer by image pickup means in a state where residual heat transferred from the substrate to the heat dissipation layer remains and thereby acquiring image data representing a temperature distribution on a surface of the heat dissipation layer, the heat dissipation layer being formed by performing a film-forming process on the surface of the substrate where residual heat that is generated when the substrate is cast remains, the image pickup means being configured to receive an emission of light (an emission spectrum) from molecules of the heat dissipation layer.

In this way, it is possible, when the image data representing the temperature distribution on the surface of the heat dissipation layer is acquired, to eliminate the need for the process for heating the heat dissipation layer by using heating means such as a xenon lamp. Therefore, it is possible to improve efficiency of the process for inspecting whether the heatsink is defective or not based on the degree of peeling of the heat dissipation layer from the surface of the substrate.

The above-described method for inspecting a heatsink preferably further includes:

comparing the image data with sampling image data and calculating a difference between temperatures of a plurality of areas within a section having a predetermined size in the image data and temperatures of areas in the sampling image data corresponding to respective areas in the image data, the sampling image data being acquired in advance and representing a temperature distribution on the surface of the heat dissipation layer in a state where the heat dissipation layer is not peeled off from the surface of the substrate; and

determining whether or not a total size of areas having a predetermined temperature difference or larger in the section is equal to or larger than a predetermined ratio with respect to the size of the section based on the calculated difference, and determining that the heatsink is a defective product in which the heat dissipation layer is peeled off from the surface of the substrate when the total size of the areas having the predetermined temperature difference or larger is equal to or higher than the predetermined ratio with respect to the size of the section.

In this way, it is possible to easily inspect whether the heatsink is defective or not based on the acquired image data.

The above-described method for inspecting a heatsink preferably further includes determining whether or not a total size of areas having a predetermined temperature or lower in the section having the predetermined size in the image data is equal to or larger than a predetermined ratio with respect to the size of the section, and determining that the heatsink is a defective product in which the heat dissipation layer is peeled off from the surface of the substrate when the total size of the areas having the predetermined temperature or lower is equal to or higher than the predetermined ratio with respect to the size of the section.

In this way, it is possible to easily inspect whether the heatsink is defective or not based on the acquired image data.

The above-described method for inspecting a heatsink preferably further includes displaying the image data and the sampling image data, which is acquired in advance and representing the temperature distribution on the surface of the heat dissipation layer in the state where the heat dissipation layer is not peeled off from the surface of the substrate.

It is possible to visually recognize a defective part by displaying the image data and the sampling image data as described above.

Another exemplary aspect is a method for producing a heatsink in which a heat dissipation layer is formed on a surface of a substrate formed by casting by performing a film-forming process, the method including:

detecting a temperature of residual heat of the substrate after the substrate is cast;

forming the heat dissipation layer by applying a film-forming resin to the surface of the substrate when the detected temperature of the residual heat of the substrate is equal to or higher than a film-forming temperature of the film-forming resin; and

shooting the heat dissipation layer by image pickup means in a state where residual heat transferred from the substrate to the heat dissipation layer remains and thereby acquiring image data representing a temperature distribution on a surface of the heat dissipation layer, the image pickup means being configured to receive an emission of light from molecules of the heat dissipation layer.

In this way, it is possible, when the image data representing the temperature distribution on the surface of the heat dissipation layer is acquired, to eliminate the need for the process for heating the heat dissipation layer by using heating means such as a xenon lamp. Therefore, it is possible to improve efficiency of the process for inspecting whether the heatsink is defective or not based on the degree of peeling of the heat dissipation layer from the surface of the substrate.

Another exemplary aspect is an inspection apparatus for a heatsink in which a heat dissipation layer is formed on a surface of a substrate formed by casting, the inspection apparatus including:

image pickup means for shooting the heat dissipation layer in a state where residual heat transferred from the substrate to the heat dissipation layer remains and thereby acquiring image data representing a temperature distribution on a surface of the heat dissipation layer, the heat dissipation layer being formed by performing a film-forming process on the surface of the substrate where residual heat that is generated when the substrate is cast remains, the image pickup means being configured to receive an emission of light from molecules of the heat dissipation layer; and

processing means for determining whether or not the heatsink is a defective product in which the heat dissipation layer is peeled off from the surface of the substrate based on the image data.

By the above-described configuration, it is possible, when the image data representing the temperature distribution on the surface of the heat dissipation layer is acquired, to eliminate the need for the process for heating the heat dissipation layer by using heating means such as a xenon lamp. Therefore, it is possible to improve efficiency of the process for inspecting whether the heatsink is defective or not based on the degree of peeling of the heat dissipation layer from the surface of the substrate.

In the above-described inspection apparatus for a heatsink, the processing means is preferably further configured to: compare the image data with sampling image data and calculate a difference between temperatures of a plurality of areas within a section having a predetermined size in the image data and temperatures of areas in the sampling image data corresponding to respective areas in the image data, the sampling image data being acquired in advance and representing a temperature distribution on the surface of the heat dissipation layer in a state where the heat dissipation layer is not peeled off from the surface of the substrate; and determine whether or not a size of areas having a predetermined temperature difference or larger in the section is equal to or larger than a predetermined ratio with respect to the size of the section based on the calculated difference, and determine that the heatsink is a defective product in which the heat dissipation layer is peeled off from the surface of the substrate when the size of the areas having the predetermined temperature difference or larger is equal to or higher than the predetermined ratio with respect to the size of the section.

Since it is determined whether the heatsink is defective or not by the processing means as described above, the heatsink can be easily inspected.

In the above-described inspection apparatus for a heatsink, the processing means preferably further configured to determine whether or not a size of areas having a predetermined temperature or lower in the section having the predetermined size in the image data is equal to or larger than a predetermined ratio with respect to the size of the section, and determine that the heatsink is a defective product in which the heat dissipation layer is peeled off from the surface of the substrate when the size of the areas having the predetermined temperature or lower is equal to or higher than the predetermined ratio with respect to the size of the section.

Since it is determined whether the heatsink is defective or not by the processing means as described above, the heatsink can be easily inspected.

Another exemplary aspect is a production system for a heatsink in which a heat dissipation layer is formed on a surface of a substrate formed by casting by performing a film-forming process, the production system for a heatsink including:

temperature detecting means for detecting a temperature of the substrate where residual heat that is generated when the substrate is cast remains;

forming means for forming the heat dissipation layer by applying a film-forming resin to the surface of the substrate when the detected temperature of the residual heat of the substrate is equal to or higher than a film-forming temperature of the film-forming resin;

image pickup means for shooting the heat dissipation layer in a state where residual heat transferred from the substrate to the heat dissipation layer remains and thereby acquiring image data representing a temperature distribution on a surface of the heat dissipation layer, the image pickup means being configured to receive an emission of light from molecules of the heat dissipation layer; and

processing means for determining whether or not the heatsink is a defective product in which the heat dissipation layer is peeled off from the surface of the substrate based on the image data.

By the above-described configuration, it is possible, when the image data representing the temperature distribution on the surface of the heat dissipation layer is acquired, to eliminate the need for the process for heating the heat dissipation layer by using heating means such as a xenon lamp. Therefore, it is possible to improve efficiency of the process for inspecting whether the heatsink is defective or not based on the degree of peeling of the heat dissipation layer from the surface of the substrate.

According to the present disclosure, it is possible to improve efficiency of a process for inspecting whether a heatsink is defective or not based on a degree of peeling of a heat dissipation layer from a surface of a substrate.

DESCRIPTION OF EMBODIMENTS

Specific embodiments to which the present disclosure is applied are described hereinafter in detail with reference to the drawings. However, the present disclosure is not limited to the below-shown embodiments. Further, the following description and drawings are simplified as appropriate for clarifying the explanation.

First Embodiment

Firstly, a configuration of a heatsink production system according to an embodiment is described.FIG. 1is a block diagram showing a control system of the heatsink production system according to this embodiment.FIG. 2shows a state in which a substrate is molded by using a mold in a heatsink manufacturing apparatus according to this embodiment.FIG. 3shows a state in which a heat dissipation layer is formed on a surface of the substrate by using forming means in the heatsink manufacturing apparatus according to this embodiment.

As shown inFIG. 1, the heatsink production system according to this embodiment1(hereinafter, also simply referred to as the production system1) includes a heatsink manufacturing apparatus2and a heatsink inspection apparatus3.

As shown inFIGS. 1 to 3, the heatsink manufacturing apparatus2(hereinafter, also simply referred to as the manufacturing apparatus2) includes a mold4, temperature detecting means5, forming means6, and processing means7. Further, the manufacturing apparatus2is used to manufacture a heatsink10in which a heat dissipation layer9is formed on a surface of a substrate8which is formed by casting. Note that the heatsink10is not limited to heatsinks provided in electric circuits, and may instead be any type of heatsink that is provided in a place where heat needs to be dissipated.

The mold4is used to mold the substrate8by casting molten metal such as aluminum. As shown inFIG. 2, for example, the mold4includes a fixed die4aand a movable die4b. Further, the movable die4bcan be moved toward and away from the fixed die4a. Alternatively, both dies of the mold4may be movable.

The mold4is closed by moving the movable die4btoward the fixed die4a, so that a cavity4cis formed inside the fixed die4aand the movable die4b. The cavity4chas a shape corresponding to the shape of the substrate8to be molded. Further, molten metal is poured into the cavity4cfrom a molten-metal inlet (not shown). Further, the mold4is opened by moving the movable die4baway from the fixed die4a, so that the substrate8molded in the cavity4cis removed from the mold4.

The temperature detecting means5detects a temperature of the cast substrate8(i.e., the molded substrate8). The temperature detecting means5is, for example, a probe-type thermometer, and detects the temperature of the surface of the substrate8by bringing its probe into contact with the substrate8. The temperature detection means5outputs the detected temperature data to the processing means7. However, the temperature detecting means5is not limited to the probe-type thermometer, and may instead be any type of thermometer capable of detecting the temperature of the surface of the substrate8.

As shown inFIG. 3, the forming means6forms a heat dissipation layer9by applying a film-forming resin to the surface of the substrate8. The forming means6is, for example, a spray nozzle that sprays a film-forming resin that can form a film (can be sintered) by residual heat that is generated when the substrate8is cast. As the film-forming resin, a thermoplastic resin such as polyamide imide (PAI) or a thermosetting resin such as epoxy-based paint or phenol-based paint can be used.

In this embodiment, the heat dissipation layer9is formed by spraying the film-forming resin on the substrate8. However, the heat dissipation layer9may instead be formed by spraying fibrous material, such as carbon, mixed with a film-forming resin, on the substrate8, or may be formed by spraying fibrous material, separately from the film-forming resin, on the substrate8.

The processing means7controls the forming means6based on temperature data of the substrate8received from the temperature detecting means5, details of which will be described later.

The inspection apparatus3for the heatsink10(hereinafter, also simply referred to as the inspection apparatus3) determines whether the heatsink10is a conforming product (e.g., a satisfactory product) or a defective product based on the degree of peeling of the heat dissipation layer9from the surface of the substrate8.

As shown inFIG. 1, the inspection apparatus3includes image pickup means11and processing means12.FIG. 4shows a state in which image data is acquired by using the image pickup means in the heatsink inspection apparatus according to this embodiment. As shown inFIG. 4, the image pickup means11shoots (i.e., photographs) the heat dissipation layer9formed on the substrate8and thereby acquires image data representing a temperature distribution on the surface of the heat dissipation layer9.

The image pickup means11includes a light-receiving element that receives an emission of light from molecules of the heat dissipation layer9. For example, the image pickup means11is an infrared thermo-camera. The image pickup means11outputs the acquired image data to the processing means12. However, although the infrared thermo-camera is used as an example of the image pickup means11, any type of image pickup means capable of receiving an emission of light from molecules of the heat dissipation layer9and thereby acquiring image data may be used.

The processing means12determines whether the heatsink10is a conforming product or a defective product based on the image data received from the image pickup means11, details of which will be described later.

Next, a method for producing a heatsink10according to this embodiment is described.FIG. 5is a flowchart showing a flow of a method for producing a heatsink according to this embodiment. As shown inFIG. 5, the method for producing a heatsink10according to this embodiment includes a process for manufacturing the heatsink10and a process for inspection thereof.

Firstly, a substrate8is formed by casting (S1). Specifically, the mold4is closed by moving the movable die4btoward the fixed die4aand molten metal is poured into the cavity4cthrough a molten-metal inlet. Then, after solidifying the molten metal, the mold4is opened by moving the movable die4baway from the fixed die4aand the substrate8is removed from the mold4as shown inFIG. 2. After that, in a state where residual heat generated in the casting remains, the substrate8is placed on a placement table13by using, for example, conveying means (not shown).

Next, the processing unit7of the production apparatus2determines whether or not a temperature of a surface of the substrate8is equal to or higher than a temperature at which a film-forming resin applied to the substrate8can form a film (can be sintered) (i.e., a predetermined film-forming temperature) (S2). Specifically, the temperature detecting means5detects the temperature of the surface of the substrate8placed on the placement table13, which is in a state where residual heat generated in the casting still remains, and outputs the detected temperature data to the processing means7.

Note that, for example, the temperature detecting means5is preferably disposed on the placement table13so that when the substrate8is placed on the placement table13, the probe of the temperature detecting means5comes into contact with the substrate8and thereby detects its surface temperature. In this way, when the substrate8is placed on the placement table13, the temperature of the surface of the substrate8can be automatically detected. Then, the processing means7determines whether or not the temperature of the surface of the substrate8in the state where the residual heat remains is equal to or higher than the film-forming temperature based on the temperature data received from the temperature detection means5.

When the temperature of the surface of the substrate8is equal to or higher than the film-forming temperature (Yes at S2), the processing means7of the manufacturing apparatus2forms a heat dissipation layer9by controlling the forming means6and thereby applying a film-forming resin to the surface of the substrate8(S3). Note that since the temperature of the surface of the substrate8is equal to or higher than the film-forming temperature, the film-forming resin forms a film on the surface of the substrate8and thereby becomes the heat dissipation layer9. In this way, the heatsink10having the heat dissipation layer9formed on the surface of the substrate8is manufactured. The manufactured heatsink10is placed on a placement table14by using, for example, conveying means (not shown) in a state where residual heat from the substrate8remains in the heat dissipation layer9.

Note that the film-forming resin is preferably applied in a period during which the temperature of the surface of the substrate8is equal to or higher than the film-forming temperature and is lower than a set temperature that is higher than the film-forming temperature by a predetermined temperature (e.g., a temperature that is 100° C. higher than the film-forming temperature).

On the other hand, when the temperature of the surface of the substrate8is lower than the film-forming temperature, the processing means7of the manufacturing apparatus2determines that the heat dissipation layer9cannot be formed (No at S2).

Next, the processing unit12of the inspection apparatus3acquires image data, which is obtained by shooting the heat dissipation layer9in the image pickup means11and represents a temperature distribution on the surface of the heat dissipation layer9(S4). Specifically, when the heatsink10is placed on the placement table14, the processing means12controls the image pickup means11so that the image pickup means11shoots (i.e., photographs) the heatsink10placed on the placement table14in the state where the residual heat of the substrate8still remains in the heat dissipation layer9.

In general, unless the heat dissipation layer9is heated by using a xenon lamp or the like, satisfactory image data cannot be acquired by the image pickup means11. However, in this embodiment, since the image pickup means11shoots the heatsink10in which the residual heat of the substrate8still remains in the heat dissipation layer9, satisfactory image data can be acquired by the image pickup means11.

The image pickup means11outputs the acquired image data representing the temperature distribution on the surface of the heat dissipation layer9to the processing unit12. It should be noted that in order to acquire satisfactory image data by the image pickup means11, the temperature of the surface of the heat dissipation layer9at the time when the heat dissipation layer9is shot (i.e., photographed) by the image pickup means11is preferably about 150° C. or higher. However, the temperature of the heat dissipation layer9at the time when the image data is acquired by the image pickup means11may be any temperature as long as satisfactory image data representing the temperature distribution on the surface of the heat dissipation layer9can be acquired.

Next, the processing unit12of the inspection apparatus3compares the acquired image data with sampling image data, which is acquired in advance and represents a temperature distribution on the surface of the heat dissipation layer9in a state where the heat dissipation layer9is not peeled off from the surface of the substrate8, and calculates a difference (a temperature difference) between temperatures of a plurality of areas within a section having a predetermined size in the image data and temperatures of areas in the sampling image data corresponding to respective areas in the image data (S5).

Specifically, as sampling image data, image data representing a temperature distribution on the surface of the heat dissipation layer9in a state where the heat dissipation layer9is not peeled off from the surface of the substrate8is acquired in advance by performing the above-described processes in the steps S1to S4. That is, the sampling image data is image data that is acquired by shooting a heatsink10that is manufactured in the same manner as the heatsink10to be inspected under the same condition as that for the heatsink10to be inspected (for example, the same elapsed time after the formation of the heat dissipation layer9, etc.) by using the image pickup means11.

Note thatFIG. 6shows a sampling image data representing a part of a temperature distribution on a surface of a heat dissipating layer in a state where the heat dissipation layer is not peeled off from a surface of a substrate in a heatsink.FIG. 7shows an image data representing a part of a temperature distribution on a surface of a heat dissipating layer in a state where a part of the heat dissipation layer is peeled off from a surface of a substrate in a heatsink. Note that inFIGS. 6 and 7, the lighter the color of an area is, the higher the temperature of the area is.

As shown inFIGS. 6 and 7, it is possible to estimate a temperature distribution on the surface of the heat dissipation layer9by using color-coding. Then, as shown inFIG. 6, when the heat dissipation layer9is not peeled off from the surface of the substrate8, the temperature distribution on the surface of the heat dissipation layer9is roughly uniform. On the other hand, as shown inFIG. 7, when a part of the heat dissipation layer9is peeled off from the surface of the substrate8, the temperature of the area where the heat dissipation layer9is peeled off is lower than the temperature of the area where the heat dissipation layer9is not peeled off.

Therefore, the processing means12of the inspection apparatus3calculates a difference between temperatures of a plurality of areas within a section having a predetermined size in the image data and temperatures of areas in the sampling image data corresponding to respective areas in the image data. That is, the processing means12calculates a temperature difference between each of the plurality of areas within the section in the image data and a respective one of the areas in the sampling image data.

Note that the section is defined by dividing a part where the heat dissipation layer9is shown in the image data into sections having a predetermined size. Further, one or a plurality of sections are present in the image data. Further, the area is defined by dividing the section and a plurality of areas are present within the section. Note that inFIG. 7, one example section C is indicated by alternate long and short dash lines and one example area A is indicated by broken lines. Note that the section and the area may be defined on a pixel basis.

The processing unit12of the inspection apparatus3repeats the above-described process in the step S5and thereby calculates a temperature difference for each area A in each section C in the entire area of the image data.

Next, the processing unit12of the inspection apparatus3determines, based on the temperature difference in each area A calculated for each section C, whether or not a total size of areas A having the predetermined temperature difference or larger in the section C is equal to or higher than a predetermined ratio with respect to the size of the section C (S6). When the total size of areas A having the predetermined temperature difference or larger in the section C is equal to or higher than the predetermined ratio with respect to the size of the section C, the processing means12of the inspection apparatus3determines that the heatsink is a defective product in which the heat dissipation layer9is peeled off from the surface of the substrate8(Yes at S6). That is, when there is a section C in which the total size of areas A having the predetermined temperature difference or larger is equal to or higher than the predetermined ratio with respect to the size of the section C in the image data, the processing means12determines that the heatsink10is defective.

On the other hand, when the total size of areas A having the predetermined temperature difference or larger in the section C is smaller than the predetermined ratio with respect to the size of the section C, the processing means12of the inspection apparatus3determines that the heatsink is a conforming product (e.g., a satisfactory product) in which the heat dissipation layer9is not peeled off from the surface of the substrate8(No at S6). That is, when there is no section C in which the total size of areas A having the predetermined temperature difference or larger is equal to or higher than the predetermined ratio with respect to the size of the section C in the image data, the processing means12determines that the heatsink10is satisfactory (i.e., is a conforming product).

In the above-described inspection method, the inspection apparatus, the production method, the production system for the heatsink10according to this embodiment, the heatsink10is shot (i.e., photographed) by the image pickup means11in the state where the residual heat of the substrate8still remains in the heat dissipation layer9in order to acquire image data representing a temperature distribution on the surface of the heat dissipation layer9. Therefore, satisfactory image data can be acquired.

Accordingly, in this embodiment, it is possible, when image data representing a temperature distribution on the surface of the heat dissipation layer9is acquired, to eliminate the need for heating process for heating the heat dissipation layer9by using heating means such as a xenon lamp. As a result, it is possible to improve efficiency of a process for inspecting whether the heatsink10is defective or not based on the degree of peeling of the heat dissipation layer9from the surface of the substrate8. In addition, it is possible to eliminate the need for the heating means such as a xenon lamp and thereby to contribute to a reduction in the production cost.

In particular, in this embodiment, since it is determined whether the heatsink10is defective or not by the processing means12of the inspection apparatus3, it is possible to easily inspect whether the heatsink10is defective or not.

Note that in this embodiment, after calculating the temperature difference in each area A in each section C in the entire area of the image data, it is determined whether or not the total size of areas A having the predetermined temperature difference or larger in each section C is equal to or higher than the predetermined ratio with respect to the size of the section C. However, it is also possible to repeat a process of calculating the temperature difference in each area A in each section C in a part of the image data and determining whether or not the total size of areas A having the predetermined temperature difference or larger in each section C is equal to or higher than the predetermined ratio with respect to the size of the section C. In this case, the inspection process can be terminated once the heatsink10is determined to be defective.

Second Embodiment

In the above-described first embodiment, it is determined whether the heatsink10is a conforming product or a defective product by using sampling image data. However, it may be determined whether the heatsink10is a conforming product or a defective product without using the sampling image data.

FIG. 8is a block diagram showing a control system of a heatsink production system according to this embodiment. In the following description, descriptions of the same components and structures as those of the first embodiment are omitted. Further, the same components as those of the first embodiment are indicated by the same symbols as those of the first embodiment.

As shown inFIG. 8, a configuration of the manufacturing apparatus2of a production system21according to this embodiment is identical to that in the production system1according to the first embodiment. However, processes performed by the processing means23of the inspection apparatus22differ from those performed by the processing means12of the production system1.

Processes performed by the processing means23of the inspection apparatus22in a method for producing a heatsink10are explained hereinafter in detail.FIG. 9is a flowchart showing a flow of a method for producing a heatsink according to this embodiment.

As shown inFIG. 9, steps S21to S24, i.e., steps up to the acquisition of image data in the heatsink production method according to this embodiment are the same as the steps S1to S4, i.e., the steps up to the acquisition of image data in the heatsink production method according to the first embodiment.

Then, in the heatsink manufacturing method according to this embodiment, after the process in the step S24, the processing means23of the inspection apparatus22determines whether or not the total size of areas A having a predetermined temperature or lower in a section C having a predetermined size in the acquired image data is equal to or larger than a predetermined ratio with respect to the size of that section C (S25).

That is, in this embodiment, it is determined whether or not temperatures of areas A in a section C in the image data is equal to or lower than the predetermined temperature. Then, it is determined whether or not the total size of areas A, which have been determined to have the predetermined temperature or lower in the section C, is equal to or higher than the predetermined ratio with respect to the size of the section C. Note that the predetermined temperature may be set to, for example, 130° C. However, the predetermined temperature can be changed as desired according to the material of the film-forming resin or the like.

When the total size of the areas A, which have been determined to have the predetermined temperature or lower in the section C, is equal to or higher than the predetermined ratio with respect to the size of the section C, the processing means23of the inspection apparatus22determines that the heatsink10is defective (Yes at S25). That is, when there is a section C in which the total size of areas A, which have been determined to have the predetermined temperature or lower in the section C, is equal to or higher than the predetermined ratio with respect to the size of the section C in the image data, the processing means23determines that the heatsink10is defective.

On the other hand, when the total size of the areas A, which have been determined to have the predetermined temperature or lower in the section C, is smaller than the predetermined ratio with respect to the size of the section C, the processing means23of the inspection apparatus22determines that the heatsink10is satisfactory (No at S25). That is, when there is no section C in which the total size of areas A, which have been determined to have the predetermined temperature or lower in the section C, is equal to or higher than the predetermined ratio with respect to the size of the section C in the image data, the processing means23determines that the heatsink10is satisfactory.

In the above-described inspection method, the inspection apparatus, the production method, the production system for the heatsink10according to this embodiment, the heatsink10is also shot by the image pickup means11in the state where the residual heat of the substrate8still remains in the heat dissipation layer9in order to acquire image data representing a temperature distribution on the surface of the heat dissipation layer9. Therefore, satisfactory image data can be acquired.

Accordingly, in this embodiment, it is possible, when image data representing a temperature distribution on the surface of the heat dissipation layer9is acquired, to eliminate the need for heating process for heating the heat dissipation layer9by using heating means such as a xenon lamp. As a result, it is possible to improve efficiency of a process for inspecting whether the heatsink10is defective or not based on the degree of peeling of the heat dissipation layer9from the surface of the substrate8. In addition, it is possible to eliminate the need for the heating means such as a xenon lamp and thereby to contribute to a reduction in the production cost.

In particular, in this embodiment, since it is also determined whether the heatsink10is defective or not by the processing means23of the inspection apparatus22, it is possible to easily inspect whether the heatsink10is defective or not.

Note that in the above-described process in the step S25, after determining the temperature in each area A in the section C in the entire area of the image data, it may be determined whether or not the total size of areas A having the predetermined temperature or lower in the section C is equal to or higher than the predetermined ratio with respect to the size of the section C. Alternatively, it is also possible to repeat a process of determining the temperature in each area A in the section C in a part of the image data and determining whether or not the total size of areas A having the predetermined temperature or lower in the section C is equal to or higher than the predetermined ratio with respect to the size of the section C. In the latter case, the inspection process can be terminated once the heatsink10is determined to be defective.

Third Embodiment

In the above-described first embodiment, the processing means12of the inspection apparatus3determines whether the heatsink10is a conforming product or a defective product. However, an operator (e.g., a worker) may determine whether the heatsink10is a conforming product or a defective product by using display means.

FIG. 10is a block diagram showing a control system of a heatsink production system according to this embodiment. In the following description, descriptions of the same components and structures as those of the first embodiment are omitted. Further, the same components as those of the first embodiment are indicated by the same symbols as those of the first embodiment.

As shown inFIG. 10, a configuration of the manufacturing apparatus2of a production system31according to this embodiment is identical to that in the production system1according to the first embodiment. However, processes performed by the processing means33of the inspection device32differ from those performed by the processing means12of the production system1. Further, the production system31also differs from the production system1because the inspection device32includes display means34.

Specifically, when the processing unit33of the inspection apparatus32receives image data from the image pickup means11, the processing unit33displays the image data and sampling image data in the display means34. In this way, an operator compares the image data displayed in the display means34with the sampling image data also displayed in the display means34. Then, for example, when an area where the temperature of the surface of the heat dissipation layer9is lower than a predetermined threshold temperature is larger than an area where the temperature of the surface of the heat dissipation layer9is determined to be lower than the predetermined threshold temperature due to an error in the image pickup means11, the operator can determine that the heatsink10is defective.

Therefore, in this embodiment, it is possible to visually recognize a defective part by displaying image data and sampling image data.

The present disclosure is not limited to the above-described embodiments, and various modifications can be made without departing the spirit and scope of the present disclosure.

In the first and second embodiments, although the image data and the sampling image data are not displayed in display means, they may be displayed in display means.

The heatsink in the above-described embodiment may have a configuration in which, for example, a heat dissipation layer is formed in a cast article such as a cylinder head of an engine.

Although the present disclosure is described as a hardware configuration in the above-described embodiments, the present disclosure is not limited to the hardware configurations. In the present disclosure, an arbitrary process can also be implemented by causing a CPU (Central Processing Unit) to execute a computer program.