Method and apparatus for reflow-soldering of print circuit boards

Abstract: A method and apparatus for reflow-soldering of print circuit boards are disclosed. A print circuit board having electronic parts with lead wires having low temperature resistance alone or together with electronic part of high temperature resistance can be soldered according to the reflow-soldering method in a specifically designed heating zone involving plural preheating chambers and a reflowing chamber while making difference in temperature between the obverse surface and the reverse surface of the board without causing any soldering failure and any environmental pollution.

Description: Background of the Invention 1. Field of the Invention: The present invention relates to a method and apparatus for soldering printed circuit boards under reflowing of solder preforms or solder pastes applied onto the boards in a heating zone (this mode of soldering will be referred to hereinafter as "reflow-soldering"). More particularly, the present invention relates to a method and apparatus for reflow-soldering printed circuit boards carrying electronic parts with lead wires of relatively low temperature resistance alone or together with electronic parts of relatively high temperature resistance such as tip parts and flat packages (referred to hereinafter sometimes simply as SMD) in a specific manner and a specifically designed heating zone without causing any soldering failure and any environmental pollution. 2. Description of the Prior Art: EP-A-0363136 discloses a soldering apparatus of a reflow type which contains a preheating chamber and a reflow chamber which are provided with a plurality of heaters for heating printed circuit boards with chips temporarily mounted thereon with solder pastes during conveyance by a conveyor. The heaters are mounted on the side walls of the chamber, extending along a direction of conveyance of the printed circuit boards. The chambers are also provided with a screening member respectively so as to prevent direct radiation of radiant heat from the heaters into the chambers and onto the printed circuit boards and to provide a uniform air flow so as to be blown uniformly onto the printed circuit boards. In the past, a soldering operation for printed circuit boards having mounted thereon SMD of relatively high temperature resistance was carried out in a reflow-soldering apparatus where the soldering operation is carried out in a high temperature atmosphere maintained at a temperature of 210-250°C. In the case of printed circuit boards having mounted thereon SMD of relatively high temperature resistance together with electronic parts with lead wires having a relatively low temperature resistance, the soldering operation was carried out by mounting SMD to a printed circuit board to which a solder paste had been applied, subjecting the board to soldering in a reflow-soldering apparatus, mounting the electronic parts with lead wires to the board, soldering the board in a jet-type soldering tank or a flow-dip type soldering tank after painting a flux to the board and subjecting it to a preliminary heating treatment, and washing the board with freon (marketed from DuPont) or the like solvent. In accordance with the recent versatility in surface-mounting technique and in accordance with the reduction in cost of printed circuit boards, electronic parts with lead wires have been soldered heretofore in a flow-dip type soldering tank or in a jet-type soldering tank. Among these electronic parts, however, those of poor temperature resistance as low as 120°C have not yet been soldered in a reflow-soldering apparatus. In the currently used reflow-soldering apparatus, the temperature of the heating zone is uniformly maintained at about 210-150°C. Accordingly, there is raised a problem such that a reflow-soldering apparatus is unsuited for soldering electronic parts with lead wires which are poor in temperature resistance as low as about 120°C. In order to solder electronic parts with lead wires in a jet-type soldering tank or a flow-dip type soldering tank, additional devices such as a flux-coating device, a preliminary heating device and a washing device become necessary. Among these additional devices, the washing device wherein freon is used as a washing solvent may cause a serious problem; when the vapor of freon leaks out of the device, such wasteful consumption of the solvent not only incurs increase in the cost of the products but also causes a bad working environment and even pollution. Thus, exclusion of the use of freon is firstly desired for soldering electronic parts with lead wires. Further, the use of a reflow-soldering apparatus is also desired for soldering both electronic parts having a high temperature resistance and electronic parts having a low temperature resistance to printed circuit boards. Under the above-mentioned circumstances, there is a great demand for the development of a new method and apparatus for carrying out soldering of electronic parts with lead wires having a poor temperature resistance by means of reflow-soldering without any accompanying washing step with freon. Brief Summary of the Invention Accordingly, it is an object of the present invention to provide a method for reflow-soldering printed circuit boards carrying electronic parts with lead wires of relatively low temperature resistance in a specifically designed heating zone. It is another object of the present invention to provide a method for reflow-soldering printed circuit boards carrying electronic parts with lead wires of relatively low temperature resistance together with electronic parts of relatively high temperature resistance without effecting any washing treatment with freon. It is still another object of the present invention to provide an apparatus for reflow-soldering printed circuit boards carrying electronic parts with lead wires of poor temperature resistance alone or together with electronic parts of high temperature resistance wherein a specifically designed heating zone is provided for soldering these electronic parts to make differences in temperature between the obverse surface and the reverse surface of the circuit boards passing through the heating zone. Other and further objects, features and advantages of the present invention will become apparent more fully from the following description. Detailed Description of the Invention As a result of extensive research made for developing a new type of method and apparatus for reflow-soldering of electronic parts with lead wires of poor temperature resistance alone or together with SMD of high temperature resistance to printed circuit boards, it has now been found that such reflow-soldering can be attained by turning upside down the printed circuit boards, the obverse surface of which optionally has SMD mounted thereon, applying solder pastes to penetrated apertures provided on the reverse side of the boards through which the lead wires of the electronic parts are to be inserted, turning the boards downside up, mounting the electronic parts onto the obverse surface of the boards with the lead wires penetrating through the solder paste and inserted into the apertures, and thereafter bringing the boards carrying the electronic parts optionally with SMD to a specifically designed heating zone where the lower portion of the zone is sufficiently heated to reflow the solder while the upper portion of the zone is gently heated under controlled conditions to prevent the electronic parts from any thermal damage. In accordance with one embodiment of the present invention, therefore, there is provided a method for reflow-soldering of printed circuit boards, which comprises taking printed circuit boards having an obverse surface which has one or more electronic parts of a first group facing upwards mounted thereon by way of soldering which are of relatively high temperature resistance, turning the printed circuit boards upside down so that the electronic parts of the first group mounted on the obverse surface face downwards, applying solder paste to penetrated apertures provided on the reverse side of the printed circuit boards through which lead wires of one or more electronic parts of a second group having relatively low temperature resistance are to be inserted, turning the boards downside up so that the electronic parts of the first group mounted on the obverse surface face upwards, inserting the lead wires of the electronic parts of the second group into the penetrated apertures opened on the obverse surface of the boards and penetrating the lead wires through the solder paste on the reverse surface, transferring the printed circuit boards to a heating zone which comprises a plurality of preheating chambers and a reflowing chamber arranged longitudinally in series, aligning the individual boards closely with or without space on a conveyer which passes through the heating zone, heating the upper half portions of the preheating chambers and the reflowing chamber facing the obverse surface of the boards at a temperature lower than the heat-resistance temperature of the electronic parts of the second group, and heating the lower half portions of the preheating chambers and the reflowing chamber facing the reverse surface of the boards so that the temperature in the reflowing chamber is higher than the melting point of the solder paste so that the solder paste on the reverse surface of the boards is molten in the reflowing chamber and solidifies after being passed through the heating zone thereby fixing the whole electronic parts to the printed circuit boards by soldering. In accordance with another (third) embodiment of the present invention, the electronic parts of the first group are temporarily mounted on the reverse surface of the printed circuit boards after applying solder paste thereonto where necessary, the boards are turned downside up, lead wires of electronic parts of the second group having low temperature resistance are inserted into apertures opened on the obverse surface of the boards and the lead wires are penetrated through the solder paste on the reverse surface. Preferably the individual boards are aligned without space on a conveyer which passes through the heating zone. According to another (second) embodiment of the present invention, there is provided an apparatus for reflow-soldering of printed circuit boards which comprises a heating zone which comprises a plurality of preheating chambers and a reflowing chamber arranged in series along the central axis of the heating zone, each chamber having an upper half portion and a lower half portion which are located in a vertically symmetrical arrangement with respect to the central axis of the heating zone, a conveying means provided with a guide rail or chain passing through the heating zone along the central axis thereof and capable of transferring to the heating zone a plurality of printed circuit boards aligned in series closely with or without space thereon, a multi-blade sirocco fan positioned in the central portion of each half portion of the preheating and reflowing chambers, a rectifying louver positioned at the exit of hot air flow in each half portion of the preheating and reflowing chambers and capable of converting turbulent flow to laminar flow, a plurality of radiant heaters mounted to each of the preheating and reflowing chambers in parallel to the direction of motion of the printed circuit boards, shielding plates provided in each of the preheating and reflowing chambers between the side walls and the guide rails or chains for protecting the chambers from radiant heat generated from the heaters, a perforated steel plate provided at the bottom of the upper half portion of the reflowing chamber for preventing the obverse surface of the printed circuit boards from absorption of the heat, and a plurality of cooling fans provided in the vicinity of the exit of the heating zone for cooling the soldered printed circuit boards; the upper half portions of the preheating and reflowing chambers being maintained at a relatively low temperature while the lower half portions of the preheating and reflowing chamber are maintained at a relatively high temperature to make a difference in temperature between them and the printed circuit boards which have electronic parts mounted on the obverse surface thereof by soldering and have temporarily mounted electronic parts of low temperature resistance with lead wires penetrating through apertures opened on the obverse surface and through solder paste applied onto the reverse surface of the printed circuit boards. Preferably, the shielding plates comprise non-movable parts and slidably movable parts capable of adjusting the distance between the side walls and the chain cover in accordance with the width of the printed circuit boards. It is also preferred that the apparatus further includes an inlet for external air provided at the top of each of the upper half portions of the preheating and reflowing chambers and a fan equipped to the inlet for compulsorily introducing external air through the inlet to prevent the ascension of hot air from the lower half portions of the preheating and reflowing chambers. Brief Description of the Drawings The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration, and thus are not limitative of the present invention, and wherein: Figs. 1(a)-1(c) are schematic views of an example of the apparatus in accordance with the second embodiment of the present invention, with Fig. 1(a) being a longitudinal cross section showing the apparatus, Fig. 1(b) being a cross section of the apparatus shown in Fig. 1(a) cut along the line I-I, and Fig. 1(c) being a cross section of the apparatus shown in Fig. 1(a) cut along the line II-II. Fig. 1(d) is a partially enlarged side cross section showing the shielding plate shown in Fig. 1(c). Figs. 2(a)-2(c) are perspective views showing the structure of a printed circuit board. Fig. 3 is a partially enlarged lateral cross section of the printed circuit hoard shown in Fig 2(c) Figs. 4(a)-4(c) are schematic diagrams showing the process of soldering a printed circuit board. Figs. 5(a) and 5(b) are schematic diagrams showing an example of a rid plate and the state of printed circuit boards aligned in series on a conveying means. Fig. 6 is a lateral cross section showing the structure of another example of the shielding plate. Figs. 7(a) and 7(b) are a plan view and a longitudinal cross section respectively showing another example of the rid plate. Figs. 8(a) and 8(b) are schematic diagrams showing the case of using a printed circuit hoard with a chassis, with Fig. 8(a) being a plan view showing a printed circuit board with chassis and Fig. 8(b) being a cross section of the printed circuit board with chassis shown in Fig. 8(a) cut along the line III-III. Fig. 9 is a schematic view of another example of the apparatus in accordance with a fourth embodiment of the present invention. Fig. 10 is a partially enlarged cross section of the preheating or reflowing chamber shown in Fig. 9. Fig. 11 is an enlarged longitudinal cross section showing the structure of a printed circuit board. Fig. 12 is a cross section showing the structure of a transfer chain. Figs. 13(a)-13(d) are schematic diagrams showing the process of soldering a printed circuit board. Fig. 14 is a graph showing the relation between the transfer time and the temperature. Detailed Description of the Invention In Figs. 1(a)-1(c) showing the structure of one example of the apparatus of this invention, the reference numeral 1 is a printed circuit board, 2 a tip part of high temperature resistance, 3 a solder paste, 7 an electronic part with lead wires of relatively low temperature resistance, 8 lead wires penetrated through an aperture, 11 a conveyer, and in this example, a transfer chain, 12 a sprocket, 21 a heating zone of the reflow-soldering apparatus, 22 a first preheating chamber, 23 a second preheating chamber, 24 a reflowing chamber, 25 a heater, 26 a shielding plate, 27 a heating area, 28 a fan, 29 a motor for the fan 28, 30 an exit of hot air, 31 a duct, 32 a rectifying louver, 33 a cooling fan, 34 a ventilating fan, 35 a path of hot air flow, 36 a radiant heater, 37 another shielding plate, and 38 a perforated steel plate. In Fig. 1(d) showing the structure of an example of the shielding plate, the reference numeral 13 is a holding nail, 14 a guide rail of the transfer chain 11 and 15 a chain cover. In Figs. 2(a)-2(c) and Fig. 3 showing the structure of the printed circuit board, the reference numeral 4 is a flat package of high temperature resistance, 5 a printed circuit and 6 a penetrated aperture formed in the boards 1. Referring to Figs. 1(a)-1(c), the heating zone 21 is a housing provided with the ventilating fan 34 and openings for entrance and exit of the transfer chain 11 and involving a plurality (two in this example) of preheating chambers 22 and 23 for preliminarily heating the printed circuit boards 1 having an obverse surface 1a and a reverse surface 1b at a temperature lower than the melting point of the solder paste and the reflowing chamber 24 where the temperature is raised higher than the melting point of the solder paste and the soldering treatment is effected. These preheating chambers 22 and 23 and the reflowing chamber 24 respectively have a pair of units which are located in a vertically symmetrical arrangement along the transfer chain 11 as a central axis. The upper preheating and reflowing chambers are designated by the reference numerals 22A, 23A and 24A while the lower preheating and reflowing chambers by the reference numerals 22B, 23B and 24B, respectively. The side walls of the preheating chambers 22A and 23A and the reflowing chamber 24A are likewise designated by the reference numerals 22a, 23a and 24a, respectively. The transfer chain 11 is supported by the guide rails 14 covered with the chain cover 15 and allowed to pass through the heating zone 21 along the central axis thereof. The transfer chain 11 is long enough and forms a loop including the portion passing through the heating zone so that it can convey a plurality of printed circuit boards continuously. The transfer chain 11 has several sprockets 12 over the full length thereof and is driven in the direction indicated by the arrow mark A. The side walls 22a, 23a and 24a are provided with a plurality of heaters 25 arranged in parallel with the direction of motion of the printed circuit boards 1 on the transfer chain 11 so that the boards 1 are efficiently heated. A sheathed heater or any type of heater capable of emitting far infrared rays is used as the heater 25. The shielding plate 26 is used for protecting the individual chambers 22, 23 and 24 from the radiant heat from the heater 25 including far infrared rays. The shielding plate 26 also serves to protect the moving printed circuit boards 1 and the tip parts 2 from the heat from the heater 25. Accordingly, the heating area 27 is formed by the shielding plate 26. The fan 28 is installed in the central part of the individual chambers 22, 23 and 24 for circulating the hot air and is driven externally by a motor 29. A multi-blade sirocco fan of a large size is particularly preferred for use as the fan 28. The exit 30 is a duct for sending a hot blast for melting the solder paste 3 while another duct 31 functions as an inlet of the hot air formed beneath the heating area 27. The exit 30 of the preheating chambers 22 and 23 and the reflowing chamber 24 is provided with a rectifying louver 32 to convert a turbulent flow formed by the fan 28 to a laminar flow. The printed circuit boards 1 taken out from the heating zone 21 where the solder paste is molten is then cooled by a plurality of cooling fans 33 whereby the molten solder is solidified to fix the electronic parts to the boards. The ventilating fan 34 is usually installed at the top of the heating zone 21, and the path 35 of hot air flow connects the heating area 27 and the fan 28. The heater 36 is provided above the rectifying louver 32 and below the transfer chain 11 to heat the reverse surface 1b of the boards 1. The shielding plate 37 for blocking the space between the chain cover 15 and the side walls 22a, 23a and 24a prevents upward flow of hot blast heated in the lower reflowing chamber 24B. The perforated steel plate 38 provided above the rectifying louver 32 of the reflowing chamber 24 has a number of perforated small holes and serves to maintain the obverse surface of the printed circuit boards at a lower temperature. Referring to Fig. 1 (d) showing the details of the shielding plate 37, the printed circuit boards 1 are supported on both side edges by holding nails 13 of the transfer chain 11 which is in turn supported by the guide rail 14, and the space between the guide rail 14 and the side wall 24a of the reflowing chamber 24 is blocked by shielding plate 37 to prevent the ascension of hot air heated in the chamber 24B at a higher temperature. This shielding plate 37 also serves to strengthen the guide rail 14. The chain cover 15 is usually interposed between the guide rail 14 and the shielding plate 37. Figs. 2(a)-2(b) show perspective views of the typical printed circuit board 1. In Fig. 2(a), board 1 carries flat packages 4 on the obverse surface 1a which have already been soldered with the solder paste 3 and have high temperature resistance. There are some penetrated apertures 6 and tip part 2 is already soldered as well on the obverse surface. Fig. 2(b) shows the reverse surface 1b of the board 1 shown in Fig. 2(a). In this case, only penetrated apertures 6 are opened on the reverse surface 1b. Fig. 2(c) shows the result of the present invention; electronic parts 7 with lead wires having low temperature resistance can thus be soldered on the obverse surface 1a without damaging any electronic characteristic property according to the present invention. Fig. 3 is a partially enlarged cross section of the printed circuit board 1 soldered in accordance with the present invention. The solder paste 3 is first applied to the printed circuit 5 on the obverse surface 1a and is soldered with the tip board 2 of high temperature strength. The print circuit board 1 is then turned upside down and the solder paste 3 is applied to penetrated aperture 6 opened on the reverse surface 1b. The board 1 is turned downside up and the electronic part 7 with lead wires having low temperature resistance is temporarily mounted to the board in such manner that the lead wires 8 are inserted into the penetrated apertures. The board 1 in this state is heated in the heating zone 21 whereby the reverse surface 1b of the board 1 is heated at a temperature above the melting point of the solder paste 3. The board 1 is then cooled by the cooling fan 33 out of the heating zone 21 to solidify the solder 3. Referring to Figs. 4(a)-4(c) showing the process of soldering a printed circuit board 1 according to the present invention, the printed circuit board 1 to be treated carries the tip board 2 which has been soldered with the solder 3 on the obverse surface 1b. The board 1 has several penetrated apertures opened on the obverse surface 1a. In Fig. 4(b), the board 1 is turned upside down and the solder paste 3 is applied, for example, by using an injector (not shown) or by using a screen plate wherein the plate is perforated in the same location as in the boards 1, onto the reverse surface 1b where the apertures 6 exist. The board is then turned downside up as shown in Fig. 4(c), and lead wires 8 of the electronic part having low temperature resistance are inserted into the apertures 6 and penetrated through the solder paste 3. The board 1 is then passed through the heating zone 21 in this state to complete the soldering treatment. In the heating zone 21, the boards 1 conveyed by the transfer chain 11 as shown in Fig. 1(d) are heated in the pre-heating chambers 22, 22A, 23 and 23A at a temperature of about 130°C. The solder already applied onto the boards 1 is not molten at this temperature. The upper reflowing chamber 24A is maintained at a temperature of about 100°C while the lower reflowing chamber 24B is heated at about 400°C by hot blast and far infrared rays generated from the radiant heater 36. In this case, the perforated steel plate 38 serves to prevent absorption of far infrared rays in the chamber 24A by the obverse surface 1a of the board 1. Further, the ascension of hot blast and radiant heat from the lower reflowing chamber 24B is prevented by the shielding plate 37. When supplying the printed circuit boards 1 to the heating zone 21, the boards 1 are aligned closely without space on the conveyer 11. If the boards 1 are aligned on the conveyer 11 with space, hot blast and radiant heat in the reflowing chamber 24B will ascend to the upper reflowing chamber 24 through the space between the boards 1 so that the temperature in the upper reflowing chamber 24A usually maintained at 100°C will be elevated giving a bad influence on the electronic characteristics of the electronic part 7 of low temperature resistance. Referring to Figs. 5(a) and 5(b) showing a plan view and a side view of the rid plate 44, respectively, the conveyer 11 must in general be filled with a rid plate 41 without space in the event the number of the boards 1 is rather small and some space is formed between them on the conveyer 11. In this case, the size of the rid plate 44 is deemed identical with the printed circuit boards to be conveyed. It is a matter of course that all of the rid plate 44 may be replaced with the printed circuit boards 1 if the number of the boards 1 to be treated is large. In Fig. 6 showing the structure of another example of the shielding plate 37, the reference numerals 1, 11, 13-15 and 24a have the same meanings as given hereinbefore. In this case, the shielding plate 37 in Fig. 1(d) is composed of plates 26a and 43 and joint parts 26b and 43a and is considered as a whole to be a combination of two parts 26a,26b and 43, 43a both in "letter L" form. As the parts 43a and 43 are slidably adjustable relative to the non-movable parts 26a and 26b, the lateral distance between the side wall 24a and the chain cover 15 can flexibly be changed according to the width of the boards 1 to be treated. In Figs. 7(a) and 7(b) showing a plan view and a side view of the structure of another example of the rid plate, respectively, the rid plate 44 has an opening 45 corresponding to the size of a smaller printed circuit board 1. When the size of the board 1 is too small to make adjustment of the shielding plate shown in Fig. 6, the rid plate of this type can effectively be used without any trouble. Figs. 8(a) and 8(b) show the case of the printed circuit board 1 accompanied by a chassis. In these figures, the reference numeral 51 is a chassis of a magnetic substance to which the print circuit board 1 is fixed, 52 a section plate of a magnetic substance formed in the chassis 51, 53 a lead wire projected outwards from the chassis 51, 54 a transfer chain, 55 a rod integrally mounted with the transfer chain 54, 56 a magnet chuck mounted to the rod 55, and 57 a permanent magnet. The other reference numerals have the same meanings as given hereinbefore. The magnet chuck 56 is held by the effect that the upper surface of section plate 52 and the chassis 51 are adsorbed by the permanent magnet 57. The chassis 51 to which the printed circuit board 1 is fixed is held by the magnet chuck 55 and is treated with the reflow-soldering apparatus (not shown) in the same steps as shown in Figs. 4(a)-4(c) by using the rid plate 44 as shown in Fig. 7 having an opening 55 corresponding to the chassis 51. Fig. 9 shows the structure of another example of the apparatus in accordance with the third and fourth embodiment of this invention. In this example, the fundamental structure of the heating zone 21 is almost identical with that shown in Fig. 1(a) except that the upper preheating chambers 22A and 23A and the upper reflowing chamber 24A are provided with an inlet 31a for external air and a fan 39 for introduction of external air and that the lower chambers 22B, 23B and 24B are provided just below the transfer chain 11 with a radiant heater 36a. The reference numeral 40 is an exhaust duct. The difference in technical effect between the apparatus shown in Fig.9 and the apparatus shown in Fig. 1(a) will become more apparent by describing the structure with reference to Fig. 10 which is an enlarged drawing of the essential part shown in Fig. 9. In Fig. 10 showing the structure of the preheating chamber 22 or 23 or the reflowing chamber 24 in detail, the inlet 31a and the fan 39 are used for introducing external air and the duct 40 is used for blowing air to the boards 1. The perforated steel plate 38a is provided below the rectifying louver 32a and the radiant heater 36 is disposed laterally to the direction of motion of the boards 1 unlike the case of the apparatus shown in Fig. 1(a). In this apparatus, the upper reflowing chamber 24A is maintained at a temperature below the melting point of the solder paste 3 while the lower reflowing chamber 24B is maintained at a temperature above the melting point of the solder paste. The operation itself for the soldering treatment is carried out in the same manner as described with respect to Figs. 1(a)-(c). Fig. 11 shows the structure of a printed circuit board in an enlarged scale which has been soldered in accordance with the third and fourth embodiment of this invention using the apparatus shown in Fig. 9. The reference numerals used in Fig. 11 have the same meanings as given hereinbefore. In Fig. 12 showing the structure of the transfer chain 11, the reference numeral 12a is a holding roll for supporting the printed circuit board 1, 15a a chain guide and 26a a shielding plate blocking the space between the side wall 22a (23a or 24a) and the chain guide so that ascension of the hot air flow and radiant heat from the lower chamber 22B (23B or 24B) is prevented. Referring to Figs.13(a)-13(d) showing the process of soldering a printed circuit board 1 in accordance with the method and apparatus shown in Fig. 9, the printed circuit board 1 is turned upside down and the solder paste 3 is applied onto the penetrated aperture 6 and onto the printed circuit 5 to which the tip part 2 is to be soldered. This state is shown in Fig.13(a). The application of the solder paste 3 onto the board 1 is carried out by using an injector or a screen plate as in Fig. 4(b). Fig. 13(b) shows temporary mounting of the tip part 2 on the printed circuit 5. The board 1 is then turned downside up and the lead wires 8 of the electronic part 7 are inserted into the aperture 6 and penetrated through the solder paste 3 on the reverse surface, as shown in Fig. 13(c). The printed circuit board 1 in this state is placed on the transfer chain 5 and passed through the heating zone 21 whereby reflow-soldering of both of the tip part 2 and the electronic part 7 is simultaneously attained as shown in Fig. 13(d). In Fig. 14, the broken line stands for the temperature characteristics of the upper chambers 22A, 23A and 24A while the solid line for the temperature characteristics of the lower chamber 22B, 23B and 24B. The printed circuit board 1 is passed through the preheating chamber 22 during the time t 1 -t 2 , through the preheating chamber 23 during the time t 2 -t 3 and through the reflowing chamber 24 during the time t 3 -t 4 . The time t 1 on the abscissa stands for the time of initiation of heating. The room temperature T 1 was 20°C. The heating is carried out during the time period of t 1 -t 2 , and the external air was introduced from the inlet 31a by the action of the fan 39 into the upper chambers 22A and 23A during the time period of t 2 -t 3 while the temperature was adjusted to T 2 =90°C which was lower than the heat resistance temperature of the electronic part 7 to suppress ascension of hot air flow from the lower chambers 22B and 23B. The lower preheating chamber 22B and 23B was heated to T 4 =150°C for preheating the board 1. During the time period of t 3 -t 4 , the upper reflowing chamber 24A was maintained at the maximum temperature of T 3 =115°C while introducing external air from the inlet 31a by driving the fan 39 to suppress ascension of hot air from the lower reflowing chamber 24B. On the other hand, the lower reflowing chamber 24B was heated at about T 5 =215°C which is higher than the melting point (180°C) of solder paste 3 whereby soldering of the tip part 2 and the lead wires 8 of the electronic part 7 was achieved. The printed circuit board 1was then taken out of the heating zone 21 and cooled by a cooling fan 33 to finish the soldering treatment. The perforated steel plate 38a effectively prevented absorption of far infrared rays from the upper chambers 22A, 23A and 24A by the obverse surface of the board. The air flow through the inlet 31a and the fan 39 prevented intrusion of the hot blast from the lower chambers 22B, 23B and 24B into the upper chambers. In the lower reflowing chamber 24B, the reverse surface of the board was heated by hot blast and far infrared rays generated from the radiant heater 36a. A result of the experiments is plotted in the graph shown in Fig. 14. From the graph, it is understood that the difference in temperature between the lower chambers and the upper chambers is about 100°C. According to the present invention, it now becomes possible to solder electronic parts of low temperature resistance by means of reflow-soldering. Thus, the washing treatment with fluon is utterly unnecessary in the present invention and no problem arises in connection with environmental pollution. When using the apparatus shown in Fig. 9. ascension of the hot blast from the lower reflowing chamber 24B is entirely suppressed by compulsory introduction of external air flow through the inlet 31a mounted to each of the upper chambers. Accordingly, it is unnecessary to align the printed circuit boards closely in serial without space on the conveyer means. The printed circuit boards can be arranged at any desired intervals on the conveyer means and this serves to simplify the soldering operation. According to this invention, reflow-soldering of printed circuit boards exclusively having electronic parts with lead wires having low temperature resistance can be carried out as well.

Claims: A method for reflow-soldering of printed circuit boards (1), which comprises taking printed circuit boards (1) having an obverse surface (1a) which has one or more electronic parts (2,4) of a first group facing upwards mounted thereon by way of soldering which are of relatively high temperature resistance, turning the printed circuit boards (1) upside down so that the electronic parts (2,4) of the first group mounted on the obverse surface face downwards, applying solder paste (3) to penetrated apertures (6) provided on the reverse surface (1b) of the printed circuit boards (1) through which lead wires (8) of one or more electronic parts (7) of a second group having relatively low temperature resistance are to be inserted, turning the boards (1) downside up so that the electronic parts (2,4) of the first group mounted on the obverse surface (1a) face upwards, inserting the lead wires (8) of the electronic parts (7) of the second group into the penetrated apertures (6) opened on the obverse surface (1a) of the boards (1) and penetrating the lead wires (8) through the solder paste (3) on the reverse surface (1b), transferring the printed circuit boards (1) to a heating zone (21) which comprises a plurality of preheating chambers (22,23) and a reflowing chamber (24) arranged longitudinally in series, aligning the individual boards (1) closely with or without space on a conveyer (11) which passes through the heating zone (21), heating the upper half portions of the preheating chambers (22A,23A) and the reflowing chamber (24A) facing the obverse surface (1a) of the boards (1) at a temperature lower than the heat-resistance temperature of the electronic parts (7) of the second group, and heating the lower half portions of the preheating chambers (22B,23B) and the reflowing chamber (24B) facing the reverse surface (1b) of the boards so that the temperature in the reflowing chamber (24) is higher than the melting point of the solder paste (3) so that the solder paste (3) on the reverse surface (1b) of the boards (1) is molten in the reflowing chamber (24) and solidifies after being passed through the heating zone (21) thereby fixing the whole electronic parts to the printed circuit boards (1) by soldering. A method according to claim 1 in which the electronic parts (2,4) of the first group are temporarily mounted on the reverse surface (1b) of the printed circuit boards (1) after applying solder paste (3) thereonto where necessary, the boards are turned downside up, lead wires (8) of electronic parts (7) of the second group having low temperature resistance are inserted into apertures (6) opened on the obverse surface (1a) of the boards and the lead wires (8) are penetrated through the solder paste (3) on the reverse surface (1b). A method according to claim 1 or claim 2 in which the individual boards (1) are aligned without space on the conveyer (11) which passes through the heating zone (21). An apparatus for reflow-soldering of printed circuit boards (1) which comprises a heating zone (21) which comprises a plurality of preheating chambers (22,23) and a reflowing chamber (24) arranged in series along the central axis of the heating zone (21), each chamber (22,23,24) having an upper half portion (22A, 23A,24A) and a lower half portion (22B,23B,24B) which are located in a vertically symmetrical arrangement with respect to the central axis of the heating zone (21), a conveying means (11) provided with a guide rail (14) or chain (11) passing through the heating zone (21) along the central axis thereof and capable of transferring to the heating zone (21) a plurality of printed circuit boards (1) aligned in series closely with or without space thereon, a multi-blade sirocco fan (28) positioned in the central portion of each half portion (22A,23A,24A,22B,23B,24B) of the preheating (22,23) and reflowing chambers (24), a rectifying louver positioned at the exit (30) of hot air flow in each half portion (22A,23A,24A,22B,23B,24B) of the preheating and reflowing chambers and capable of converting turbulent flow to laminar flow, a plurality of radiant heaters (36) mounted to each of the preheating (22,23) and reflowing chambers (24) in parallel to the direction of motion of the printed circuit boards (1), shielding plates (37) provided in each of the preheating (22,23) and reflowing chambers (24) between the side walls and the guide rails (14) or chains for protecting the chambers (22,23,24) from radiant heat generated from the heaters (36), a perforated steel plate (38) provided at the bottom of the upper half portion (24A) of the reflowing chamber for preventing the obverse surface (1a) of the printed circuit boards (1) from absorption of the heat, and a plurality of cooling fans (33) provided in the vicinity of the exit of the heating zone (21) for cooling the soldered printed circuit boards (1) ; the upper half portions of the preheating and reflowing chambers being maintained at a relatively low temperature while the lower half portions of the preheating and reflowing chambers are maintained at a relatively high temperature to make a difference in temperature between them and the printed circuit boards (1) which have electronic parts mounted on the obverse surface (1a) thereof by soldering and have temporarily mounted electronic parts of low temperature resistance with lead wires penetrating through apertures (6) opened on the obverse surface (1a) and through solder paste (3) applied onto the reverse surface (1b) of the printed circuit boards (1). An apparatus according to claim 4, wherein the shielding plates (37) comprise non-movable parts and slidably movable parts capable of adjusting the distance between the side walls (22a,23a,24a) and the chain cover (15) in accordance with the width of the printed circuit boards (1). An apparatus according to claim 4 or claim 5 which further includes an inlet for external air provided at the top of each of the upper half portions of the preheating and reflowing chambers and a fan (34) equipped to the inlet for compulsorily introducing external air through the inlet to prevent the ascension of hot air from the lower half portions of the preheating (22B,23B) and reflowing chambers (24B).

Inventors: KONDO KENSHI, KONDO, KENSHI
Applicants: NIPPON DENNETSU KEIKI KK, NIHON DEN-NETSU KEIKI CO., LTD.
Application year: 1991
Main classification: H05K13
IPC codes: H05K13, H05K3, B23K1