Patent ID: 12240153

DESCRIPTION OF THE EMBODIMENTS

Hereinafter, embodiments of the present invention are described with reference to the drawings. The drawings of each embodiment are for purposes of illustration, the dimensions and shape of each part are schematically shown, and the technical scope of the present invention should not be interpreted as being limited to the embodiments.

First Embodiment

A configuration of a resin sealing apparatus1according to an embodiment of the present invention is described with reference toFIGS.1and2.FIG.1is a diagram schematically showing a configuration of a resin sealing apparatus according to a first embodiment.FIG.2is a plan view schematically showing a workpiece and a resin supply pattern in a resin sealing mold.

Each drawing may be assigned with a Cartesian coordinate system including X-axis, Y-axis and Z-axis for convenience to clarify the relationship between the drawings and to help understand the positional relationship between members. The direction of the Z-axis arrow is an upward direction, and the direction opposite to the direction of the Z-axis arrow is a downward direction.

The resin sealing apparatus1is an apparatus used for resin-sealing (molding) a workpiece10with a resin13. The resin sealing apparatus1includes a resin supply apparatus100that applies (supplies) the resin13for resin sealing onto an object to be coated (for example, the workpiece10or a release film RF), and a resin sealing mold200that heats and pressurizes the resin for curing. The workpiece10includes, for example, a substrate11and elements12arranged on the substrate11, and the elements12are arranged in a first direction X and a second direction Y, respectively. In the following description, in a plan view of the workpiece10from a positive direction (hereinafter referred to as “upward direction”) side of a third direction Z, a region from an edge of the substrate11to an element12at the outermost edge is referred to as “external region of the workpiece10”. In the external region of the workpiece10, a region sandwiched by the resin sealing mold200is referred to as “external region10A”, and a region closer to the element12side than the external region10A is referred to as “external region10B”.

The configurations of the substrate11and the element12are not limited. As an example, the substrate11may be a semiconductor wafer, and the element12may be a semiconductor chip flip-chip mounted on the substrate11. In this case, a gap is present between the substrate11and the element12when the resin13is supplied, but the resin is filled in this gap by heating and pressurizing. The present invention is not limited to this aspect, and may also be applied when, for example, the element12is simply mounted on the substrate11without a gap therebetween, or when an underfill resin is filled between the substrate11and the element12. In addition, the element12may be a multilayer body in which a plurality of semiconductor chips are laminated at intervals in the third direction Z, or may be an element other than a semiconductor element (MEMS device, electronic device, or the like). The arrangement of the element12on the substrate11is not limited. For example, the element12may be wire-bonded to the substrate11, or may be detachably fixed to the substrate11. The substrate11may be a resin substrate or a glass substrate, or may be an interposer substrate, a lead frame, a carrier plate with an adhesive sheet, or the like. In a plan view of the workpiece10from above, for example, the planar shape of the substrate11is circular and the planar shape of the element12is rectangular, but the planar shapes of the substrate11and the element12are not limited thereto. For example, the planar shape of the substrate may be rectangular, and the planar shape of the element may be polygonal or circular. Two or more types of elements having different shapes may be arranged on the workpiece.

The resin supply apparatus100includes an acquisition unit110, a supply unit120, a calculation unit130, a drive unit140, and a stage150.

The acquisition unit110acquires structural information (for example, information about the shape, size, and the like of a cavity201) of the cavity201constituting an internal space of the resin sealing mold200that is filled with the resin13. The acquisition unit110acquires the structural information by input from, for example, an external terminal or the like. The method for acquiring the structural information of the cavity201is not limited to the above method. For example, the acquisition unit110may read a code or the like assigned to the resin sealing mold200, and thereby acquire structural information corresponding to the code or the like from a database recorded in advance.

The acquisition unit110acquires arrangement information (for example, information about the shape, size, arrangement direction, number, interval, and the like of the elements12) of the elements12on the workpiece10(more specifically, the substrate11) in addition to the structural information of the cavity201. For example, the acquisition unit110acquires the arrangement information of the elements12by imaging the workpiece10and analyzing the image of the workpiece10. The acquisition unit110may acquire the arrangement information for each workpiece, or may acquire the arrangement information for each lot having a plurality of workpieces. Note that, the method for acquiring the arrangement information of the elements12is not limited to the above method. For example, the acquisition unit110may read a code or the like assigned to the workpiece10, and thereby acquire arrangement information corresponding to the code or the like from a database recorded in advance. In addition, the acquisition unit110may acquire the arrangement information by inputting from the external terminal or the like. Additionally, the acquisition unit110may detect a position of a V notch or the like in the workpiece10such as a wafer to acquire the orientation of the workpiece10. The resin supply apparatus100can also supply the resin13described later after adjusting the orientation of the workpiece10based on the orientation of the workpiece10acquired by the acquisition unit110.

The supply unit120supplies the resin13onto the object to be coated (the workpiece10or the release film RF). The supply unit120is, for example, a dispenser for discharging the liquid resin13. The supply unit120includes a syringe121in which the resin13is stored, a pusher (piston)122that is inserted inside the syringe121and can push out the resin13, and a pinch valve123that opens or closes a nozzle at the front end of the syringe121. The supply unit120is provided with a configuration in which the used syringe121can be replaced with a new syringe121when the resin13stored in the syringe121is used up. Note that, the supply unit120is not limited to the above configuration, and may include a switching valve instead of the pinch valve123. In addition, the supply unit120may be configured to prepare two liquids separately and mix and supply them on site. For example, the supply unit120may be a feeder for discharging powdery and granular resin.

The calculation unit130calculates the resin supply pattern (the shape of the resin13applied on the object to be coated) based on the shape of the cavity201of the resin sealing mold200obtained from the acquisition unit110. The resin supply pattern calculated by the calculation unit130has a plurality of linear paths14extending along the first direction X and arranged in the second direction Y.

As shown inFIG.2, in a plan view of the workpiece10from above (hereinafter, simply referred to as “in a plan view”), the plurality of linear paths14are inclined with respect to an axis of symmetry SM that divides the cavity201in line symmetry. Because the axis of symmetry SM of the cavity201is parallel to the first direction X, the plurality of linear paths14are inclined from the first direction X toward the second direction Y, and an angle of inclination of the linear path14from the first direction X is an acute angle. Each of the mutually adjacent linear paths14is inclined in a direction opposite to the first direction X, and one of the mutually adjacent linear paths14is inclined with respect to the other linear path. That is, one of the mutually adjacent linear paths14approaches the other linear path as the one linear path is directed to a positive direction side or a negative direction side of the first direction X.

For example, on the side on which one of the mutually adjacent linear paths14approaches the other linear path, the end portions of the mutually adjacent linear paths14overlap. That is, the mutually adjacent linear paths14are connected to each other on the element12at the outermost edge of the workpiece10, and are formed as one continuous linear line. The resin supply pattern is one continuous linear line as a whole, and the resin13can be supplied with one stroke in the entire resin supply pattern. In other words, the resin supply pattern is formed as one linear pattern by repeatedly folding back the inclined linear paths so as to make the inclined linear paths to be connected at the end portions. In addition, an angle formed by the mutually adjacent linear paths14is constant regardless of the position of the workpiece10. Additionally, the mutually adjacent linear paths14extend to the element12at the outermost edge of the workpiece10. Therefore, the resin13can be supplied to the entire workpiece10.

In a plan view of the workpiece10, a region19between the mutually adjacent linear paths14in the plurality of linear paths14is opened to the outside of the workpiece10, on a side on which one of the mutually adjacent linear paths14is separated from the other linear path. On a side opposite to the side on which the region19is opened to the outside of workpiece10, the region19between the mutually adjacent linear paths14is blocked by the linear paths14that are connected to each other.

A corner portion of the resin supply pattern may have a sharp shape or an R shape.

The resin supply pattern is described more specifically by taking a first linear path14A, a second linear path14B adjacent to the first linear path14A, and a third linear path14C adjacent to the second linear path14B as examples. In a plan view of the workpiece10, the first linear path14A and the third linear path14C are inclined at an acute angle in a clockwise direction from the first direction X, and the second linear path14B is inclined counter clockwise from the first direction X. The second linear path14B approaches the first linear path14A on the negative direction side of the first direction and approaches the third linear path14C on the positive direction side of the first direction X. The end portions of the first linear path14A and the second linear path14B on the negative direction side of the first direction X are overlapped on the element12at the outermost edge, and the end portions of the second linear path14B and the third linear path14C on the positive direction side of the first direction X are overlapped on the element12at the outermost edge. In other words, the second linear path14B is connected to the first linear path14A at an end portion on a side approaching the first linear path14A (the negative direction side of the first direction X), and is connected to the third linear path14C at an end portion on a side approaching the third linear path14C (the positive direction side of the first direction X). The resin13can be supplied with one stroke along the first linear path14A, the second linear path14B, and the third linear path14C. An angle formed by the first linear path14A and the second linear path14B is substantially the same as an angle formed by the second linear path14B and the third linear path14C.

In a plan view of the workpiece10, a region19A between the first linear path14A and the second linear path14B is blocked on the negative direction side of the first direction X (the side on which the first linear path14A approaches the second linear path14B), and is opened to the outside of the workpiece10on the positive direction side of the first direction X (the side on which the first linear path14A is separated from the second linear path14B). In contrast, a region19B between the second linear path14B and the third linear path14C is blocked on the positive direction side of the first direction X (the side on which the third linear path14C approaches the second linear path14B), and is opened to the outside of the workpiece10on the negative direction side of the first direction X (the side on which the third linear path14C is separated from the second linear path14B). The region19A between the first linear path14A and the second linear path14B is continuous in the first direction X, rather than being partitioned by other portions of the resin supply pattern. The region19B between the second linear path14B and the third linear path14C is also continuous in the first direction X.

The drive unit140moves the supply unit120with respect to the fixed workpiece10along the resin supply pattern. Specifically, the drive unit140includes an upper base portion141, a first motor142M, a first moving portion142, a second motor143M, a second moving portion143, a third motor144M, a third moving portion144and a fourth motor122M.

The first moving portion142is configured to be movable in the first direction X relative to the upper base portion141, the second moving portion143is configured to be movable in the second direction Y relative to the first moving portion142, and the third moving portion144is configured to be movable in the third direction Z relative to the second moving portion143. Specifically, the upper base portion141has a rail, and the first moving portion142has a slider that slides on the rail of the upper base portion141by being driven by the first motor142M. The first moving portion142has a rail, and the second moving portion143has a slider that slides on the rail of the first moving portion142by being driven by the second motor143M. The second moving portion143has a rail, and the third moving portion144has a slider that slides on the rail of the second moving portion143by being driven by the third motor144M. The syringe121of the supply unit120is fixed to the third moving portion144. The third moving portion144has a rail, and a pusher122of the supply unit120has a slider that slides on the rail of the third moving portion144by being driven by the fourth motor122M. That is, the first motor142M controls the moving amount and moving speed of the supply unit120in the first direction X, the second motor143M controls the moving amount and moving speed of the supply unit120in the second direction Y, and the third motor144M controls the moving amount and moving speed of the supply unit120in the third direction Z. Besides, the fourth motor122M controls the discharge amount and discharge speed of the resin13from the supply unit120by controlling the moving amount and moving speed of the pusher122.

Moreover, the drive unit140is not limited to the above, and at least one of the workpiece10and the supply unit120may be moved relative to the other along the resin supply pattern. For example, the drive unit140may fix the supply unit120and move the stage150on which the workpiece10is placed relative to the supply unit120, or may move both the workpiece10and the supply unit120.

The workpiece10is placed on the stage150. The stage150includes, for example, a weighing scale. The resin supply apparatus100adjusts the amount of supply of the resin13while measuring, by the weighing scale of the stage150, the weight of the resin13supplied onto the workpiece10. Specifically, the drive of the first motor142M to the fourth motor122M of the drive unit140is changed based on the weighing result of the weighing scale. With the above configuration, the resin13can be supplied onto the workpiece10in an arbitrary shape and in an arbitrary amount by moving the syringe121at an arbitrary moving speed while supplying the resin13at an arbitrary discharge speed. For example, if the moving speed in the first direction X and the second direction Y is increased, the amount of supply within a predetermined length can be reduced even at the same discharge speed, and if the moving speed in the first direction X and the second direction Y is decreased, the amount of supply within a predetermined length can be increased even at the same discharge speed.

The resin sealing mold200includes a pair of molds (a lower mold210and an upper mold220) for sealing the workpiece10with a resin by using compression molding technique. In the present embodiment, the resin sealing mold200has an upper mold cavity structure in which the cavity201is arranged inside the upper mold220. In addition, the resin sealing mold200includes a sealing ring203(for example, an O-ring) for sealing the inside of the resin sealing mold200(the space between the lower mold210and the upper mold220). Moreover, although not shown, the resin sealing apparatus1includes a pressure adjusting portion (for example, a vacuum pump) for adjusting the internal pressure of the resin sealing mold200, and a temperature adjusting portion (for example, a heater) for adjusting the internal temperature (molding temperature).

The upper mold220includes a chase221, a cavity piece223, a clamper225surrounding the cavity piece223, and a chamber block227surrounding the clamper225at an interval. The cavity piece223is fixed to the chase221. The clamper225protrudes from the cavity piece223toward the lower mold210and constitutes the cavity201together with the cavity piece223. The clamper225is connected to the chase221via a spring and is configured to be slidable with respect to the cavity piece223. When the mold is clamped, the external region10A of the workpiece10is sandwiched between the clamper225and the lower mold210. On the lower surface of the clamper225(the surface facing the lower mold210), a plurality of recessed air vents226that connect the space on the chamber block227side and the cavity201are arranged. The plurality of air vents226extend radially around the cavity201. The air in the cavity201is discharged through the air vents226between the clamped upper mold220and lower mold210. Note that, in each drawing, the air vent226is illustrated as having a deep depth for the sake of understanding, but in fact, the air vent226is formed to have a depth (for example, about several micrometres) at which the air or gas in the mold is discharged but the resin13does not flow out. Exhaust holes228connected to a pump to discharge air in the cavity201are arranged in a portion of the chamber block227. The exhaust holes228of the chamber block227extend radially around the cavity201. The sealing ring203is sandwiched between the chamber block227and the lower mold210.

In the clamped resin sealing mold200, at least one of the plurality of air vents226may be arranged on an extension line of the region19between the mutually adjacent linear paths14in the plurality of linear paths14. For example, as shown inFIG.2, the air vents226are arranged on an extension line of the region19A between the first linear path14A and the second linear path14B.

Next, a method for manufacturing a resin-sealed product using the resin sealing apparatus1according to the present embodiment is described with reference toFIGS.3to6.FIG.3is a flowchart showing a method for manufacturing a resin-sealed product using the resin sealing apparatus according to the first embodiment.FIG.4is a cross-sectional view schematically showing a resin on the workpiece immediately after being set inside the resin sealing mold.FIG.5is a cross-sectional view schematically showing a resin being spread by the resin sealing mold.FIG.6is a cross-sectional view schematically showing a resin filled in the cavity by heating and pressurizing. Note that, for simplicity of explanation, the chamber block227is not shown inFIGS.4to6.

First, the structural information of the cavity201is acquired (S11). For example, the model number of the resin sealing mold200used is input to the acquisition unit110from the external terminal, and the structural information of the cavity201corresponding to the model number is acquired from the database. At this time, the arrangement information of the elements12on the workpiece10can also be acquired from the acquisition unit110. For example, the acquisition unit110acquires the arrangement information of the elements12arranged in the first direction X and the second direction Y by imaging the workpiece10and analyzing the image of the workpiece10.

Next, the resin supply pattern is calculated based on the structural information of the cavity201(S12). For example, the calculation unit130calculates, based on the structural information of the cavity201registered by the acquisition unit110, the resin supply pattern according to pre-registered rules (for example, the angle of inclination of the linear path14with respect to the axis of symmetry SM of the cavity201, the thickness and length of the linear path14, and the like), and determines desirable moving route, moving speed, and the like of the supply unit120. Moreover, the structural information of the cavity201includes the inner peripheral dimension of the cavity, the depth of the cavity at the time of final molding, and the like.

Then, the resin13is supplied onto the workpiece10along the resin supply pattern (S13). Here, the supply unit120is moved relative to workpiece10by driving the drive unit140based on the resin supply pattern in a state that the workpiece10is positioned in the first direction X, the second direction Y, and the rotation direction centered on the Z axis. When the supply unit120moves to a supply start position (one end of the resin supply pattern), the pinch valve123is opened while pushing the pusher122against the syringe121, and the supply of the resin13is started. When the supply unit120that continues to supply the resin13is moved to a supply end position (the other end of the resin supply pattern) along the resin supply pattern, the pinch valve123is closed while the pushing of the pusher122against the syringe121is stopped, and the supply of the resin13is ended.

Subsequently, the release film RF is set in the upper mold220, and the workpiece10is set in the lower mold210. The release film RF is carried into the opened resin sealing mold200so as to cover the cavity201. The release film RF may be supplied, for example, by being fed out from a roll of unused film arranged in front of the mold and wound by a roll of used film arranged at the rear of the mold. After discharging air from a gap between the cavity piece223and the clamper225and an intake hole in the upper mold220(not shown), the release film RF is adsorbed to the upper mold220. In addition, the workpiece10to which the resin13is supplied is carried into the opened resin sealing mold200. The air is discharged from the intake hole in the upper mold220(not shown), the workpiece10is adsorbed to the lower mold210.

Next, the resin13is spread by mold clamping (S15).

First, as shown inFIG.4, for example, the external region10A of the workpiece10having the flip-chip mounted elements12and the substrate11is sandwiched between the clamper225and the lower mold210. At this time, although not shown, the sealing ring203is sandwiched between the chamber block227and the lower mold210. A shallow dug portion arranged on the lower surface of the clamper225forms the air vent226between the lower mold210and the clamper225(between the workpiece10and the clamper225), and the space (the cavity201) inside the clamper225and the space outside the clamper225are connected through the air vent226. Accordingly, the air in the mold shown inFIG.4is discharged to the outside of the chamber block227.

Next, as shown inFIG.5, the resin13is spread by the cavity piece223in the depressurized mold. At this time, the resin13can enter the gap between the element12and the release film RF as well as the gap between the workpiece10and the flip-chip mounted element12to perform underfill. In the process of spreading the resin13, the resin13is filled in the region19between the mutually adjacent linear paths14from the side on which one linear path approaches the other linear path. On the workpiece10, the region19between the mutually adjacent linear paths14is not divided until the filling of the resin13is completed, so that air can be discharged from the air vent226.

Then, the cavity piece223is relatively lowered by performing mold clamping, and as shown inFIG.6, the resin13spreads to the whole part the cavity201, and fine spaces such as the gap between the element12and the substrate11or the like are also filled with the resin13. Accordingly, the resin13is filled up to the front of the air vent226. Here, by softening the resin13while heating it with a heater (not shown) and pressurizing the resin13with the cavity piece223, the resin13is filled (molded) in the cavity, and at the same time, the gap between the workpiece10and the flip-chip mounted element12is underfilled with the resin13.

Finally, the resin13is cured by continuing heating and pressurizing (curing) for a predetermined time (S16). In this way, the sealing of the workpiece10with a resin is completed.

According to the configuration described in the above embodiment, the resin supply pattern calculated by the calculation unit130based on the shape of the cavity201has a plurality of the linear paths14, and one of the mutually adjacent linear paths14is inclined with respect to the axis of symmetry SM of the cavity201, and the other linear path is inclined with respect to the one linear path. The region19between the mutually adjacent linear paths14is opened to the outside of the workpiece10at least on the side on which one of the adjacent linear paths14is separated from the other linear path. Accordingly, when the resin13is spread in the resin sealing mold200so as to seal the workpiece10with a resin, the air remaining inside the resin sealing mold200and the gas generated from the resin13can be discharged through the region19. Therefore, it is possible to suppress the occurrence of defects (for example, air traps or non-filling) due to the containment of air or the like caused by the resin13. Accordingly, when it is difficult for the resin13to enter a fine portion of the workpiece10due to the presence of air or the like, for example, the filling of the resin13into the gap between the flip-chip mounted element12and the substrate11is promoted and the occurrence of poor filling can be suppressed.

The second linear path14B located between the first linear path14A and the third linear path14C is connected to an end portion of the first linear path14A on one end portion and is connected to an end portion of the third linear path14C on the other end portion. In addition, the resin supply pattern is one continuous linear line. Accordingly, by having a shape in which adjacent linear paths are not connected to each other at least on either end portion side, the resin13can be supplied with one stroke while discharging air. Therefore, the resin13can be efficiently supplied onto the workpiece10by continuously discharging the resin13without the need for stopping the discharge of the resin13during the supply.

The resin supply apparatus100may include the acquisition unit110for acquiring the shape of the workpiece10, the arrangement information of the elements12, and the like. The calculation unit130may calculate the resin supply pattern in consideration of the shape of the workpiece10and the arrangement information of the elements12. Accordingly, the resin13can efficiently enter the fine space such as a gap between the substrate11and the element12, or the like, and the occurrence of sealing failure can be suppressed.

The amount of supply of the resin13may be adjusted by taking into account the arrangement information of the elements12. For example, the resin supply pattern may be calculated so that the amount of supply of the resin13in a region having a small ratio of the occupied area per unit area (hereinafter referred to as “area ratio”) of the elements12on the workpiece10is greater than the amount of supply of the resin13in a region having a large area ratio of the elements12. Accordingly, it is possible to suppress occurrence of defects caused by a shortage of the resin13when the resin13is heated and pressurized.

The mutually adjacent linear paths14extend to the element12at the outermost edge of the workpiece10and are connected to each other on the element12at the outermost edge. Accordingly, as compared with a resin supply pattern in which the mutually adjacent linear paths14are connected to each other on an element12which is on the inner side of the element12at the outermost edge, it is possible to suppress occurrence of defects caused by the shortage of the resin13in a space over the external region10B of the workpiece10in which the required amount of the resin13is large due to the absence of the elements12.

The air vent226is arranged on the extension line of the region19between the mutually adjacent linear paths14. Accordingly, the air vent is not blocked until the region19between the mutually adjacent linear paths14is completely filled with the resin13, and air can be discharged from the inside of the resin sealing mold200.

In the present embodiment, the acquisition unit110acquires the arrangement information of the elements12and the structural information of the cavity201. However, the acquisition unit110may acquire only the structural information of the cavity201without acquiring the arrangement information of the elements12. In addition, the acquisition unit for acquiring the arrangement information of the elements12and the acquisition unit for acquiring the structural information of the cavity201may be arranged separately.

In addition, the resin supply pattern is not limited to the above. It is sufficient that at least one of the mutually adjacent linear paths14is inclined with respect to the axis of symmetry SM of the cavity201, and one of the mutually adjacent linear paths14is inclined with respect to the other linear path. The mutually adjacent linear paths14may be connected to each other on the external region10B of the workpiece10. The mutually adjacent linear paths14may also extend to the element12which is on the inner side of the element12at the outermost edge of the workpiece10except for extending to the element12at the outermost edge, and the mutually adjacent linear paths14may be connected to each other on the element12which is on the inner side of the element12at the outermost edge. The mutually adjacent linear paths14may be separated from each other, and the region19between the mutually adjacent linear paths14may be opened to the outside of the workpiece10on both the positive direction side and the negative direction side of the first direction X. An angle formed by the mutually adjacent linear paths14at the center of the workpiece10in the second direction Y may be different from an angle formed by the mutually adjacent linear paths14at an end portion of the workpiece10in the second direction Y.

Hereinafter, a variation example of the resin supply pattern and a configuration of a resin sealing apparatus according to another embodiment of the present invention are described. It should be noted that the matters common to the first embodiment can also be applied to each of the following aspects, the description thereof is omitted, and only the differences are described. In particular, the same configurations are designated by the same reference signs, and the same configurations and the same actions and effects are not mentioned sequentially.

FIGS.7to12show schematic plan views of resin supply patterns according to different variation examples. As shown inFIGS.7to12, external regions20A,30A,40A,50A,60A,70A are respectively referred to a region sandwiched by the resin sealing mold; external regions20B,30B,40B,50B,60B,70B are respectively referred to a region closer to the element22,32,42,52,62,72side than the external regions20A,30A,40A,50A,60A,70A; reference numerals21,31,41,51,61,71represent a substrate; reference numerals23,33,43,53,63,73represent a resin; and reference numerals29,39,49,59,69,79represent region between the linear paths.

As shown inFIG.7, in a plan view of a workpiece20, one of the mutually adjacent linear paths24in the plurality of linear paths24is inclined with respect to the axis of symmetry SM of the cavity, and the other linear path is inclined with respect to the one linear path and parallel to the axis of symmetry SM of the cavity.

As shown inFIG.8, in a plan view of a workpiece30, mutually adjacent linear paths34are connected by a relay path35extending in the second direction Y. The relay path35has, for example, an arc shape. By connecting the mutually adjacent linear paths34via the relay path35, the degree of freedom in design regarding an interval between the mutually adjacent linear paths34and an angle formed by the mutually adjacent linear paths34is improved. Moreover, the relay path35is not limited to the above as long as the relay path35does not form a constriction in the region39between the mutually adjacent linear paths34and does not partition the region39. For example, the relay path35is linear and may form a sharp shape at a connection portion with the linear path34.

As shown inFIG.9, in a plan view of a workpiece40, the mutually adjacent linear paths44are separated from each other. A region49between the mutually adjacent linear paths44is opened to the outside of the workpiece40on a side on which the other linear path approaches one of the mutually adjacent linear paths44. That is, the region49between the mutually adjacent linear paths44is opened to the outside of the workpiece40on both the positive direction side and negative direction side of the first direction X that is parallel to the axis of symmetry SM of the cavity.

As shown inFIG.10, elements52A and elements52B larger than the elements52A are arranged on a workpiece50. The elements52A are shorter than the elements52B, and the area ratio of the elements52A is smaller than the area ratio of the elements52B. Thus, a region where the elements52A are arranged requires more resin53than a region where the elements52B are arranged. Therefore, by making a linear path54extending over the region where the elements52A are arranged thicker than a linear path54extending over the region where the elements52B are arranged, occurrence of defects caused by poor filling can be suppressed.

As shown inFIG.11, in a plan view of a workpiece60, an angle formed by mutually adjacent linear paths64at the center of the workpiece60in the second direction Y is larger than an angle formed by the mutually adjacent linear paths64at an end portion of the workpiece60in the second direction Y. Accordingly, by making the amount of supply of the resin63at the end portion of the workpiece60that has a large external region60B larger than the amount of supply of the resin63at the center of the workpiece60that has a small external region60B, occurrence of defects caused by poor filling can be suppressed.

As shown inFIG.12, in a plan view of a workpiece70, an angle formed by the mutually adjacent linear paths74at the center of the workpiece70in the second direction Y is smaller than an angle formed by the mutually adjacent linear paths74at an end portion of the workpiece70in the second direction Y. Accordingly, the width of the open end of the region79between the mutually adjacent linear paths74at the center of the workpiece70is substantially the same as the width of the open end of the region79between the mutually adjacent linear paths74at the end portion of the workpiece70. Thus, the occurrence of defects caused by poor filling can be suppressed by appropriately adjusting the width of the region79between the mutually adjacent linear paths74.

Even in the variation examples of the first embodiment shown inFIGS.7to12, the occurrence of defects caused by poor filling can be suppressed as in the first embodiment shown inFIG.2. Moreover, the resin supply patterns ofFIGS.2and7to12described above can be appropriately combined and applied to one workpiece.

FIG.13is a variation example of a workpiece, and shows a rectangular workpiece10for use in panel level packaging (PLP). As shown inFIG.13, in a plan view of a workpiece80, a substrate81(workpiece80) has a rectangular shape having a pair of short sides and a pair of long sides. A linear path84extends along the short side of the substrate81, and more specifically, the linear path84is inclined with respect to the short side of the substrate81and is arranged along the long side of the substrate81. Accordingly, as compared with a configuration in which the linear path84extends along the long side of the substrate81, the length of a region89between the mutually adjacent linear paths84is shortened, and the region89is blocked due to the contact between the resins13in the linear path84during the process of spreading a resin83, and thus air can be suppressed from being caught in the resin83. Further, the variation example shown inFIG.13can be appropriately applied to each of the above resin supply patterns. As shown inFIG.13, external regions80A is referred to a region sandwiched by the resin sealing mold; external regions80B is referred to a region closer to the element82side than the external region80A.

Second Embodiment

A configuration of a resin supply pattern according to a second embodiment is described with reference toFIG.14.FIG.14is a diagram schematically showing a configuration of a resin sealing apparatus according to the second embodiment.

In the present embodiment, the object to be coated is a release film RF that delivers the supplied resin13to the workpiece10. The release film RF is placed on the stage150, and the drive unit140moves the supply unit120based on the information about the shape of a cavity901acquired by the acquisition unit110, and the resin13is supplied onto the release film RF. A resin sealing mold900has a lower mold cavity structure which includes a lower mold910that has the cavity901and an upper mold920. The release film RF is set in the lower mold910, and the workpiece10is set in the upper mold920. The lower mold910has a cavity piece913and a clamper915that constitutes the cavity901, and an air vent916is arranged on the upper surface of the clamper915(the surface facing the upper mold920) when the mold is clamped.

Next, a method for manufacturing a resin-sealed product using a resin sealing apparatus9according to the present embodiment is described with reference toFIG.14.FIG.15is a flowchart showing a method for manufacturing a resin-sealed product using the resin sealing apparatus according to the second embodiment.

First, the structural information of the cavity901is acquired (S91). Next, the resin supply pattern is calculated based on the structural information of the cavity901(S92). When calculating the resin supply pattern in consideration of the arrangement information of the elements12, take into account that the resin supply pattern on the release film RF is inverted on the workpiece10. Then, the resin13is supplied onto the release film RF along the resin supply pattern (S93). Next, the release film RF is set in the lower mold910, and the workpiece10is set in the upper mold920(S94). At this time, the release film RF and the workpiece10are positioned in the rotation directions centered on the first direction X, the second direction Y, and the Z axis, which can obtain effects similar to those obtained by supplying the resin13applied on the release film RF to a position corresponding to the elements12on the workpiece10. Subsequently, by closing the mold, the resin13is brought into contact with the elements12and the substrate11while the air is discharged from the chamber of the mold, and the resin13is spread by mold clamping (S95). The resin13on the release film RF set in the lower mold910is pressed against the workpiece10set in the upper mold920, and the resin13is spread while being sandwiched between the workpiece10and the release film RF. Here, it is considered that by discharging air before bringing the resin13into contact with the elements12or the substrate11, air traps can be prevented even if a closed space is formed by the contact between the resins13on the release film RF. However, when the resin13is spread, the gas generated by heating the resin13remains, which may cause poor filling. In contrast, by arranging the path for discharging gas as in the present embodiment, the occurrence of defects such as an air trap caused by gas can be suppressed. Subsequently, the resin13is cured by heating and pressurizing (S96). In this way, the same effect as that of the above-described present invention can be obtained even when the mold has the lower mold cavity structure.

Further, in the aspect described in the embodiment, any one or an appropriate combination of a plurality of the resin supply patterns described in the first embodiment can be applied.

As described above, according to one aspect of the present invention, it is possible to provide a resin supply apparatus, a resin sealing apparatus, and a method for manufacturing a resin-sealed product, which can suppress occurrence of defects.

A resin supply apparatus according to one aspect of the present invention is a resin supply apparatus for supplying a resin onto an object to be coated which is arranged in a lower mold of a resin sealing mold. The resin supply apparatus includes: a calculation unit for calculating a resin supply pattern based on the shape of a cavity of the resin sealing mold; and a supply unit for supplying a resin to the object to be coated along the resin supply pattern. The resin supply pattern has a plurality of linear paths. One of mutually adjacent linear paths in the plurality of linear paths is inclined with respect to an axis of symmetry that divides the cavity in line symmetry, and the other one of the mutually adjacent linear paths in the plurality of linear paths is inclined with respect to the one linear path. A region between the mutually adjacent linear paths in the plurality of linear paths is opened to the outside of the object to be coated, at least on a side on which the other linear path is separated from the one linear path.

According to this aspect, the region between the adjacent linear paths functions as a flow passage for discharging air. In addition, when the resin is spread on the object to be coated, the resin is gradually filled in the region between the mutually adjacent linear paths from a side on which the other linear path approaches one linear path toward a side on which the other linear path is separated from the one linear path. Thus, while the resin is spreading on the object to be coated, a region surrounded by the resin in all directions is not generated, and the region between the adjacent linear paths functions as a flow passage for discharging air. Therefore, air remaining in the region between the adjacent linear paths and gas generated from the resin can be suppressed from being caught in the resin, and occurrence of defects caused by poor filling can be suppressed.

In the above aspect, the plurality of linear paths have a first linear path, a second linear path adjacent to the first linear path, and a third linear path adjacent to the second linear path. The second linear path may be connected to the first linear path at an end portion on a side approaching the first linear path, and may be connected to the third linear path at an end portion on a side approaching the third linear path.

In the above aspect, the resin supply pattern may be one continuous linear line.

In the above aspect, a corner portion of the resin supply pattern may have an R shape.

In the above aspect, the region between the mutually adjacent linear paths in the plurality of linear paths may be opened to the outside of the object to be coated on a side on which the other linear path approaches the one linear path.

In the above aspect, the object to be coated may be a workpiece to be sealed using a supplied resin.

In the above aspect, the object to be coated may be a release film that delivers supplied resin to a workpiece.

In the above aspect, the resin supply apparatus may further include an acquisition unit for acquiring the shape of the cavity of the resin sealing mold and providing the acquired information to the calculation unit.

In the above aspect, the calculation unit may calculate the resin supply pattern in consideration of the shape of a workpiece sealed by the resin supplied to the object to be coated.

In the above aspect, the calculation unit may calculate the resin supply pattern in consideration of arrangement information of elements on the workpiece sealed by the supplied resin.

In the above aspect, the axis of symmetry may extend in a direction in which the elements are aligned.

In the above aspect, the resin supply pattern may be calculated so that the amount of supply of a resin in a region in the workpiece having a small area ratio of the elements is larger than the amount of supply of a resin in a region having a large area ratio of the elements.

In the above aspect, the plurality of linear paths include a set of linear paths adjacent to each other at the center of the workpiece and another set of linear paths adjacent to each other at an end portion of the workpiece, and an angle formed by the set of linear paths may be larger than an angle formed by the other set of linear paths.

In the above aspect, the plurality of linear paths includes a set of linear paths adjacent to each other at the center of the workpiece and another set of linear paths adjacent to each other at an end portion of the workpiece, and an angle formed by the set of linear paths may be smaller than an angle formed by the other set of linear paths.

A resin sealing apparatus according to one aspect of the present invention includes the resin supply apparatus according to any one of the above aspects, and a resin sealing mold for sealing elements on a workpiece with a resin. The resin sealing mold has a cavity in which a resin is filled and a plurality of air vents for discharging air from the cavity. The object to be coated is arranged in the resin sealing mold so that at least one of the plurality of air vents is located on an extension line of a region between mutually adjacent linear paths in the plurality of linear paths.

According to this aspect, when the mold is clamped and the resin is heated and pressurized, the air vents arranged on the extension line of the region between the linear paths are not blocked until the region between the mutually adjacent linear paths is completely filled with a resin. Therefore, in the resin sealing mold, the air remaining in the region between the adjacent linear paths and the gas generated from the resin can be suppressed from being caught in the resin, and the occurrence of defects caused by poor filling can be suppressed.

A method for manufacturing a resin-sealed product according to one aspect of the present invention includes supplying a resin onto an object to be coated which is arranged in a lower mold of a resin sealing mold. The method for manufacturing a resin-sealed product includes: calculating a resin supply pattern based on the shape of a cavity of the resin sealing mold; and supplying a resin to the object to be coated along the resin supply pattern. The resin supply pattern has a plurality of linear paths. One of the mutually adjacent linear paths in the plurality of linear paths is inclined with respect to an axis of symmetry that divides the cavity in line symmetry, and the other one of the mutually adjacent linear paths in the plurality of linear paths is inclined with respect to the one linear path. A region between the mutually adjacent linear paths in the plurality of linear paths is opened to the outside of the object to be coated, at least on a side on which the other linear path is separated from the one linear path

According to this aspect, the region between the adjacent linear paths functions as a flow passage for discharging air. In addition, when the resin is spread on the object to be coated, the resin is gradually filled in the region between the mutually adjacent linear paths from a side on which the other linear path approaches one linear path toward a side on which the other linear path is separated from the one linear path. Thus, while the resin is spreading on the object to be coated, a region surrounded by the resin in all directions is not generated, and the region between the adjacent linear paths functions as a flow passage for discharging air. Therefore, the air remaining in the region between the adjacent linear paths and the gas generated from the resin can be suppressed from being caught in the resin, and occurrence of defects caused by poor filling can be suppressed.

In the above aspect, the object to be coated may be a workpiece to be sealed using a supplied resin.

In the above aspect, the object to be coated may be a release film that delivers supplied resin to a workpiece.

Effect

According to the present invention, it is possible to provide a resin supply apparatus, a resin sealing apparatus, and a method for manufacturing a resin-sealed product, which can suppress occurrence of defects.

The embodiments described above are for purposes of facilitating the understanding of the present invention, and should not be interpreted as limiting the present invention. Each element included in the embodiment and its arrangement, material, condition, shape, size, and the like are not limited to the illustrated ones, and can be changed as appropriate. In addition, the configurations shown in different embodiments can be partially replaced or combined.