Reflow Apparatus Flux Extraction System
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Solution Overview
Problem
Existing reflow oven systems face challenges in efficiently removing vaporized contaminants, such as flux residues, without interrupting the surface mount production process, as these contaminants tend to condense in cooling zones and impair cooling functions, requiring periodic filter cleaning that halts production.
Innovation Solution
A two-stage flux extraction and filtration system is introduced, comprising a first stage with cooling fins and a filter device to condense and trap contaminants, and a second stage with a coil and collection container to further remove contaminants, allowing for continuous operation by periodically heating and collecting the condensed materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If condensate filters are used to remove vaporized contaminants from the reflow oven, then contaminant removal effectiveness is improved, but production continuity deteriorates due to periodic cleaning interruptions
Solution Approach 1:
The patent extracts the contaminant collection function from the main reflow oven system by using a separate, removable condensate filter assembly. This allows the filter to be removed and cleaned externally without interrupting the reflow oven's operation, thus maintaining production continuity while effectively removing vaporized contaminants
Solution Approach 2:
The patent implements a system where condensate and contaminants are collected in a removable filter assembly that can be periodically discarded and replaced. The collected contaminants are recovered and disposed of separately, allowing the filter system to be quickly reset without stopping production
2Temperature
If cooling zones are used to cool substrates, then cooling function is improved, but harmful factors worsen due to condensate buildup and dripping
Solution Approach 1:
The patent extracts the condensate collection function from the cooling zones by positioning removable condensate filters within or adjacent to the cooling zones. These filters capture vaporized contaminants before they can condense and drip onto substrates, maintaining the cooling function while eliminating the harmful dripping effect
Solution Approach 2:
The patent introduces condensate filters as intermediary components between the heating zones (where vaporization occurs) and the cooling zones (where condensation would occur). These filters intercept and collect vaporized contaminants, preventing them from reaching the cooling zones and forming harmful condensate
3Object-affected harmful factors
If flux extraction systems are implemented, then contaminant removal is improved, but device complexity increases
Solution Approach 1:
The patent segments the flux extraction system into simple, modular condensate filter assemblies that can be independently installed and removed. Each filter assembly is a discrete component with straightforward structure, avoiding the need for complex integrated extraction systems while maintaining effective contaminant removal
Solution Approach 2:
The patent employs disposable or easily replaceable condensate filter assemblies that can be quickly removed and replaced when saturated. This approach avoids the need for complex, expensive, and difficult-to-maintain permanent extraction systems, reducing overall device complexity while maintaining effective contaminant removal
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
The system effectively removes vaporized contaminants from the reflow oven without interrupting production, reducing the risk of contamination and residue buildup, and allows for easy cleaning of collection containers without stopping the process, enhancing operational efficiency and product integrity.
Implementation Method 1
The cooling device has a plurality of cooling fins to cool the vapor stream entering into the first stage unit
Implementation Method 2
contaminants in the vapor stream condense on the cooling fins when passing the vapor stream over the cooling fins
Implementation Method 3
periodically heating the cooling fins to remove contaminants from the cooling fins
Implementation Method 4
heating the cooling fins to remove contaminants from the cooling fins
Data Source
AI summary
A reflow apparatus for solder joining electronic components to a substrate includes a reflow chamber, a conveyor to convey a substrate within the chamber, at least one heating element to provide heat to reflow solder on the substrate, and at least one system to remove contaminants generated from the reflow solder. The system is coupled with the chamber for passage of a vapor stream from the chamber through the system. The system comprises a contaminant collection unit in fluid communication with the vapor stream. The contaminant collection unit includes a coil and a collection container. The coil is configured to receive cooled gas therein. The arrangement is such that when introducing cooled gas in the coil, contaminants in the vapor stream condense on the coil, and when ceasing the introduction of cooled gas in the coil, contaminants in the vapor stream are released from the coil and collected in the collection container. Other embodiments and methods for removing contaminants are further disclosed.