Vacuum Soldering Pump Control for Void Prevention
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Solution Overview
Problem
Existing vacuum reflow apparatuses face issues with sudden changes in vacuum conditions during soldering, leading to voids bursting and flux, component, and solder scattering, while gentle evacuation gradients require longer times to reach target vacuum levels.
Innovation Solution
A vacuum soldering apparatus with a control method that dynamically changes pump output from low to high based on set gradients, allowing for rapid evacuation to specified vacuum levels, preventing void bursting and scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the vacuum pump drives at constant high output to reach target vacuum quickly, then productivity is improved, but the sudden vacuum change causes voids to burst and scatter flux, components and solder
Solution Approach 1:
The patent applies dynamics by making the pump output adjustable rather than fixed. The control unit dynamically changes the pump output from low to high based on the current vacuum degree, allowing the system to adapt its evacuation speed to the actual process needs. This resolves the contradiction by enabling both gentle initial evacuation (when voids are large) and rapid final evacuation (when vacuum is near target), thus improving both reliability and productivity.
Solution Approach 2:
The patent changes the operational parameter of pump output based on the vacuum degree. By monitoring the vacuum degree and adjusting the pump output accordingly, the system optimizes the evacuation process at different stages. This parameter change approach allows the system to prevent void bursting during early evacuation while achieving rapid vacuum attainment later, resolving the productivity-reliability contradiction.
2Reliability
If the evacuation gradient is made gentle to prevent void bursting, then soldering quality is improved, but the time to reach target vacuum level increases
Solution Approach 1:
The system dynamically adjusts the evacuation gradient based on real-time vacuum degree feedback. When the vacuum degree is low (early stage), the pump operates at low output to create a gentle gradient that prevents void bursting. When the vacuum degree approaches the target level, the pump output increases to high, creating a steeper gradient that reduces total evacuation time. This dynamic adjustment resolves the contradiction between gentle evacuation and fast evacuation.
Solution Approach 2:
The evacuation process is divided into multiple stages with different pump outputs. The control unit periodically adjusts the pump operation based on vacuum degree thresholds, creating a multi-phase evacuation sequence. This periodic action allows the system to apply different evacuation intensities at appropriate times, preventing void bursting while minimizing total evacuation time.
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
Enables high-quality vacuum soldering with reduced voids by gradually defoaming/deaerating molten solder, preventing flux and component scattering, and optimizing throughput by achieving target vacuum pressures quickly.
Implementation Method 1
the vacuum pump is driven to create the vacuum condition
Implementation Method 2
any voids which remain in the solder while the solder is melted to be removed by defoaming and/or deaerating effect
Implementation Method 3
any voids which remain in the solder while the solder is melted to be removed by defoaming and/or deaerating effect
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
In a vacuum soldering apparatus and a control method thereof according to the present invention, in order to prevent flux scattering or solder scattering when voids are defoamed and/or deaerated from molten solder by evacuating a chamber to a target degree of vacuum as well as in order to be able to perform brief evacuation, an evaluation control of a pump is performed. The evaluation control of the pump is performed in which the plural evacuation control properties (#1 through #4) with the gradients θ plotting the degrees of vacuum (pressure P) in relation to evacuation time (time t) when a chamber is evacuated by a predetermined pump output, are previously prepared; and the control are changed from evacuation control property of small pump output to evacuation control property of large pump output based on the initially set gradient θ in the evacuation control property.