Flux Management System for Wave Solder Machine Contaminant Removal
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Solution Overview
Problem
Inert atmosphere tunnel systems in wave solder machines prevent the evacuation of vaporized flux contaminants, leading to their accumulation on internal components, requiring extensive maintenance.
Innovation Solution
A two-stage flux management system with an air-to-air heat exchanger for condensing vaporized flux and a packed bed of steel balls for filtering small particles, allowing for continuous removal and recirculation of clean gas within the tunnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inert atmosphere tunnel system is used in a wave solder machine, then flux volatile contaminants are not able to be evacuated by an exhaust system, but these contaminants collect on internal components within the tunnel requiring extensive maintenance
Solution Approach 1:
The patent extracts harmful flux contaminants from the inert atmosphere tunnel by introducing a separate gas stream that carries contaminants out of the tunnel and into a collection system, thereby removing the harmful accumulation problem while maintaining the inert atmosphere benefits
Solution Approach 2:
The patent uses an intermediary gas stream (process gas) that acts as a mediator between the inert atmosphere and the external environment, carrying contaminants out of the tunnel without disrupting the inert atmosphere needed for proper soldering operation
2Ease of repair
If a flux management system is implemented to remove contaminants, then maintenance requirements are reduced, but system complexity increases
Solution Approach 1:
The flux management system is segmented into distinct functional components including a gas introduction system, a collection system with filters and condensers, and a recirculation system, allowing each component to be independently maintained and replaced without shutting down the entire wave solder machine
Solution Approach 2:
The system incorporates automatic filtration and condensation mechanisms that continuously remove contaminants without requiring manual intervention, and the modular design allows components to be serviced independently while the machine continues operating
3Object-affected harmful factors
If contaminants are removed from the tunnel, then flux build-up damage is prevented, but the system requires additional components for continuous operation
Solution Approach 1:
The flux management system operates continuously during wave soldering operation, with gas constantly circulating through the tunnel to capture contaminants and transport them to collection devices, ensuring uninterrupted protection against flux build-up without stopping production
Solution Approach 2:
The system discards captured flux contaminants through filtration and condensation mechanisms while recovering and recirculating the clean process gas back into the tunnel, maintaining continuous contaminant removal efficiency without excessive resource consumption
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively removes vaporized contaminants from wave solder machine tunnels, reducing maintenance costs and preventing damage from flux build-up, while maintaining continuous operation.
Implementation Method 1
an air-to-air heat exchanger using compressed air as a cooling medium to condense flux vapor on contact with the air-to-air heat exchanger
Implementation Method 2
an air-to-air heat exchanger using compressed air as a cooling medium to condense flux vapor
Implementation Method 3
a packed bed of steel balls contained within a perforated sheet metal structure
Implementation Method 4
a packed bed of steel balls contained within a perforated sheet metal structure
Data Source
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AI summary
A wave solder machine is configured to perform a wave solder operation on an electronic substrate. The wave solder machine includes a fluxing station configured to apply flux onto the electronic substrate, a pre-heating station configured to heat the electronic substrate, a wave soldering station configured to attach electronic components to the electronic substrate with solder, and a conveyor configured to transport substrates through a tunnel passing through the fluxing station, the pre-heating station and the wave soldering station. The wave solder machine further includes a flux management system configured to remove contaminants from the tunnel. The flux management system is in fluid communication with the tunnel for passage of a vapor stream from the tunnel through the flux management system and back to the tunnel. Methods of performing a wave solder operation are further disclosed.