塑封基礎(chǔ)知識(shí)培訓(xùn)課件

1、塑封基礎(chǔ)知識(shí)培訓(xùn) 樹 脂 Resin填充料 Filler 硬化劑Curing agent 添加劑Additive 混 合Pre-mixing 加熱混練 Kneading 冷 卻Cooling 粉 碎 Crushing 混 合Blending錠粒成型Tableting 秤量包裝 Weigh Package EMEProduct1- EME的原材料和生產(chǎn)過程1.1-Raw Material Support for EME In CCP(藍(lán)色為CCP自產(chǎn)） PHENOLIC NOVOLAC RESIN線性酚醛樹脂PHENOL苯酚EMEEpichlorohydrin環(huán)氧氯丙烷（表氯醇） Bisphno

2、l A雙酚ABROMINATED EPOXY溴化環(huán)氧樹脂F(xiàn)ILLER填充劑ADDITIVE添加劑OTHERS其它EPOXY CRESOL NOVOLAC RESIN鄰甲酚醛環(huán)氧樹脂環(huán)氧樹脂填充劑添加劑粉碎、混合、攪拌塑封料塑封料生產(chǎn)流程2-EME固化（交聯(lián)）過程2.1-樹脂體系2.2- EME固化（交聯(lián)）程度行為曲線3-在充填過程中，EME黏度行為曲線 Viscosity behavior during filling at 175 CTimeHot hardness 預(yù)熱 成型 后固化EME系列膠化時(shí)間&螺旋流動(dòng)長度v.s.模溫EME Series Gel Time & Spiral Flo

3、w v.s. Molding Temperature 4-成型 Molding冷凍保存 (10)Cold Storage (10)回溫 Stabilizing(20-30,50-70%RH )成型 Molding再保存(必要時(shí))Re-Storage在成型車間,原封不動(dòng).需回溫16-24 小時(shí).(溫度平衡)Keep the package sealed. Thaw16-24 hours in molding room condition*需重新包裝好*回溫后72小時(shí)內(nèi)用完Seal up package as before it was opened.*不要用手直接碰觸黑膠. *72小時(shí)內(nèi)使用完畢

4、Dont touch compound with your bare hand.4.1.黑膠準(zhǔn)備 Compound PreparationStorage Life VS Temp.EME存儲(chǔ)壽命隨著存儲(chǔ)溫度的提高顯著短縮。成型條件 Molding Conditions a.錠粒預(yù)熱Preheating of Pellet 預(yù)熱前的準(zhǔn)備Preparation for stable preheating *回溫充分，趕走濕氣Stabilization of compound temperature and humidity *預(yù)熱時(shí)間Preheat time： 2040sec.(根據(jù)預(yù)熱設(shè)備調(diào)整D

5、epending on pre-heater) *精確的設(shè)定Precise adjustment of： 滾筒間的距離Distance between rollers 電極間的距離/水平度Distance/horizontal level of electrode如何測量預(yù)熱溫度How to measure the preheat temp. *確認(rèn)錠粒表面溫度優(yōu)于確認(rèn)錠粒內(nèi)部溫度 Check the surface temp. of pellets rather than inside of pellets此法之優(yōu)點(diǎn)Advantages of this method： 預(yù)熱后可快速的進(jìn)行測量

6、 Quick checking right after heating 不會(huì)受黑膠本身的影響 Not affected by the heat from compound itself 可以快速、個(gè)別地測量錠粒溫度Can check the temp. pellet to pellet individuallyb.殘留餅厚度/錠重 Cull Thickness / Pellet Weight通過獲得合適的殘留餅厚度確認(rèn)錠粒重量是否合適ADJUST PELLET WEIGHT TO GET PROPER CULL THICKNESS理想的厚度 IDEAL THICKNESS太厚TOO THICK

7、黑膠的浪費(fèi)，cull固化不完全(COMPOUND LOSS, UNCURED CULL)太薄TOO THIN(不完全充填I(lǐng)NCOMPLETE FILL)轉(zhuǎn)進(jìn)方向 Transfer directionc.轉(zhuǎn)進(jìn)壓力TRANSFER PRESSURE 正確的判斷表壓和實(shí)際轉(zhuǎn)進(jìn)壓力之間的關(guān)系 ACCURATE ADJUSTMENT IS REQUIRED GAUGE PRESSURE VS ACTUAL PRESSURE 注意NOTE 實(shí)際的轉(zhuǎn)進(jìn)壓力需要周期性地用壓力計(jì)校正ACTUAL PRESSURE SHOULD BE CHECKED PERIODICALLY WITH DILLON GAUGE

8、(FORCE GAUGE) 轉(zhuǎn)進(jìn)頭和轉(zhuǎn)進(jìn)筒需要周期性地進(jìn)行更換PLUNGER HEAD AND TRANSFER POT SHOULD BE REPLACED PERIODICALLY. (PREVENT PRESSURE LOSS) 轉(zhuǎn)進(jìn)壓力Transfer Pressure 表壓和實(shí)際的轉(zhuǎn)進(jìn)壓力Gauge pressure v.s. Actual pressurePr x Sr = Pp x SpSr =(Dr/2)2Sp =(Dp/2)2Dr : Diameter of RamDp : Diameter of PlungerPp : actual pressure to PKG.Pr :

9、 oil pressure shown on Gage with unit kg/cm2(Also all Ram pressure ( = Pr x Sr ) is shown on the same gage with unit ton) Die surface area doesnt relate in ideal.But complexed runner and cavity structure will make pressure loss.d.轉(zhuǎn)進(jìn)速度/時(shí)間TRANSFER SPEED/TIME 轉(zhuǎn)進(jìn)速度是通過轉(zhuǎn)進(jìn)距離除于轉(zhuǎn)進(jìn)時(shí)間得到的TR. SPEED IS CALCULATED

10、 WITH TR. DISTANCE AND TR.TIME TR. SPEED (CM/SEC)= TR. DISTANCE (L) L = =r2hn/R2 2r : 錠粒直徑PELLET DIAMETER h: 錠粒高度PELLET HEIGHT n: 錠粒的顆數(shù) NO. OF PELLETS 2R: 轉(zhuǎn)進(jìn)筒直徑 POT DIAMETER錠粒的直徑應(yīng)該要和轉(zhuǎn)進(jìn)筒的直徑相近PELLET DIAMETER SHOULD BE CLOSE TO POT DIAMETER EXAMPLE 2R=50mm 2r =48mm e.后固化POST MOLD CURE烘箱OVEN 為了加熱的均勻性，烘箱

11、必需是通過熱風(fēng)扇加熱OVEN WITH INSIDE HEATING FAN IS DESIRABLE FOR UNIFORM HEATING固化溫度和時(shí)間CURE TEMP. AND TIME后固化時(shí)間要在烘箱達(dá)到合適的溫度后開始計(jì)時(shí)CURE TIME SHOULD BE COUNTED AFTER REACHING PROPERTEMP. LEVEL后固化后各個(gè)主要參數(shù)的比較Post Mold Cure Comparison5-EME 成型常見問題及其對(duì)策充填不良( Incomplete Fill) 氣孔(Voids)麻點(diǎn)(Pin Hole)溢料（Resin Bleed）流痕(Flow m

12、ark)黏模(Stick)開裂(Crack)沖線(Wire sweep)5-1 EMC封裝成型不良相關(guān)因素充填不良( Incomplete Fill)充填不良( 趨向性）充填不良( 隨機(jī)性）氣孔（Void）外部氣孔（air vent側(cè)）外部氣孔（gate側(cè)）內(nèi)部氣孔麻點(diǎn)在封裝成形后,封裝體的表面有時(shí)會(huì)出現(xiàn)大量微細(xì)小孔,而且位置都比較集中,看卜去是一片麻點(diǎn)。這些缺陷往往會(huì)伴隨其他缺陷同時(shí)出現(xiàn),比如充填不良、氣孔等。這種缺陷產(chǎn)生的原因主要是料餅在預(yù)熱的過程中受熱不均勻,各部位的溫差較大,注入模腔后引起固化反應(yīng)不一致,以至于形成麻點(diǎn)缺陷。錠粒無間隙,預(yù)熱不均錠粒有間隙(均勻擺放),預(yù)熱均勻麻點(diǎn)溢料(

13、Resin bleed/Flash)溢料流痕(Flow Mark)黏 模黏 模開裂開裂沖線(wire sweep)結(jié)語 塑封成形的不良種類很多，在不同的封裝形式上有不同的表現(xiàn)形式，發(fā)生的幾率和位置也有很大的差異，產(chǎn)生的原因也比較復(fù)雜，并且互相牽連，互相影響，所以應(yīng)該在分別研究的基礎(chǔ)上，綜合考慮，制定出相應(yīng)的解決方法與對(duì)策。踏實(shí)，奮斗，堅(jiān)持，專業(yè)，努力成就未來。7月-227月-22Tuesday, July 26, 2022弄虛作假要不得，踏實(shí)肯干第一名。22:42:1022:42:1022:427/26/2022 10:42:10 PM安全象只弓，不拉它就松，要想保安全，常把弓弦繃。7月-22

14、22:42:1022:42Jul-2226-Jul-22重于泰山，輕于鴻毛。22:42:1022:42:1022:42Tuesday, July 26, 2022不可麻痹大意，要防微杜漸。7月-227月-2222:42:1022:42:10July 26, 2022加強(qiáng)自身建設(shè)，增強(qiáng)個(gè)人的休養(yǎng)。2022年7月26日10:42 下午7月-227月-22追求卓越，讓自己更好，向上而生。26 七月 202210:42:10 下午22:42:107月-22嚴(yán)格把控質(zhì)量關(guān)，讓生產(chǎn)更加有保障。七月 2210:42 下午7月-2222:42July 26, 2022重規(guī)矩，嚴(yán)要求，少危險(xiǎn)。2022/7/26 22:42:1022:42:1026 July