Reflow apparatus and method

Abstract: The present invention provides a reflow apparatus and method which can make the running direction of the internal gas flow in a heating section within a reflow furnace constant. A circulating gas path is formed in a heating unit (U) which collects and moves the gas flow (B) from a sirocco fan (11) up to the rear side of the heating unit (U) and at the same time, drops the raised gas flow towards a circuit board (2) on a transfer path from the front side of the heating unit (U). Moreover, a plurality of straightening plates (16) are arranged above the transfer path of the heating unit (U) so as to guide down the hot gas flow (B) running forward to the circuit board (2) on the transfer path. A blow-down nozzle (17) is further constituted of a plurality of plate materials (19) aligned in rows in the transferring direction of circuit boards and having an inverse U-shaped cross section. The blow-down nozzle (17) is arranged below the straightening plates (16) to feed the hot gas flow (B) to the whole surface of the circuit board (1) in the vertical direction uniformly.

Description: BACKGROUND OF THE INVENTION The present invention relates to a reflow apparatus and method which jets out the hot gas flow to a circuit board thereby to solder the circuit board while transferring the circuit board into a plurality of sections in a reflow furnace along a transfer path. US-A-4 909 430 representing the closest prior art from which the invention proceeds discloses a reflow soldering method and an apparatus thereof, wherein an air flow fan is provided at the bottom of the apparatus, i.e. below a work transporting conveyor so as to produce a minus pressure to draw or pull air into the apparatus in a manner that the drawn air may flow in a constant volume and at a constant speed from up to down through a predetermined path and flow down through a heater provided in the path to be heated up substantially to a set temperature of the heater. The heated air further flows down to contact a work such as a base board having electronic parts mounted thereon and transported by the conveyor and heat up the work. The air is then sent out of the above mentioned air circulating path by the fan into another path which allows the air to flow from down to up into an air chamber located above the heating, the air chamber is of a sufficient capacity to remarkably reduce the flowing speed of the air to stagnate the same therein for preparation of the next air circulation through the above mentioned air circulating paths to heat up the work as the latter is transported by the conveyor. In US-A-5 147 083, it is shown a convection braze furnace for brazing aluminium heat exchangers in an inert gas rich atmosphere including entrance and exit vestibules forming atmosphere barriers of suspended stainless steel strips. The interior of the braze furnace is divided into multiple zones for progressively heating the heat exchangers to a brazing temperature and then cooling the heat exchangers in the final zone. An impeller circulates the heated intent gas atmosphere within each zone to accelerate heat transfer. A chain type conveyor supports the heat exchangers as they are moved through the braze furnace. An isolated return tube surrounds the lower return side of the conveyor chain as it passed through the braze furnace. The braze furnace housing is comprised of inner and outer shells having an inert gas pressurized cavity interstitial therebetween. The inner shell includes a plurality of expansion strips having generally ellipsoidal corner expansion joints. JP-A-04253566 discloses a reflow soldering device wherein a work is transported through a work feed-in section, a preheating chamber, a reflow chamber and a work ejecting section by a conveyor. The work is preheated in the preheating chamber, and the solder paste of the work is subjected to reflow by a high-temperature inert gaseous atmosphere in the reflow chamber by which a wiring board and parts are soldered. The inert gas injected from an inert gas injection port into the reflow furnace is discharged to the outside through apertures of partition plates provided in the work feed-in section and the ejection section, but the amount of the inert gas to be discharged is throttled by the narrowed apertures of the partition plates so as to decrease the amount of the inert gas to be injected and to maintain a low oxygen concentration in the reflow furnace. Accordingly, the passing rate of the inert gas increases, and the possibility of the infiltration of the outdoor air into the furnace is low. In JP-A-62151268, it is shown a vapor phase type soldering device wherein a carrying conveyor is provided between a carrying-in part and a carrying-out part of a printed circuit board, and also a conveyor frame of the conveyor is installed so as to be freely slidable. Also, an opening/closing plate is provided integrally with the conveyor frame on the outside opening surface of the carrying-in port and carrying-out port parts, and also the opening/closing plate is opened and closed by interlocking with the change of width of the conveyor frame. By following the change of the width size of the circuit board, the intervall of the conveyor frame is adjusted by operating a handle, and also, by interlocking with it, the opening/closing plate is moved and adjusted so as to reduce leakage of vapor from the opening surface. A further conventional reflow apparatus of the type referred to above is disclosed, for example, in JP-A-2-137691 wherein a circuit board is heated in the gas and soldered while being transferred in a plurality of sections within a reflow furnace along a transfer path. In the reflow apparatus of this kind, as shown in Fig. 25, a cream solder is fed to a circuit board 61 beforehand. After the circuit board 61 is put into a reflow furnace 63 from an entrance of a transfer path 62, the circuit board 61 is moved through a first preheating section 64, a second preheating section 65, a reflow section 66 and a cooling section 69 along the transfer path. The circuit board 61 is gradually heated in the first and second preheating sections 64, 65, and then further heated in the reflow section 66 thereby to be soldered. Reference 67 indicates heaters arranged every predetermined distance immediately above the transfer path 62 in each of the first preheating section 64, second preheating section 65 and reflow section 66. In the above-described conventional reflow apparatus, since the heaters 67 are located close to the transfer path 62, an gas flow 70 heated passing through the vicinity of the heaters 67 and an gas flow 71 which passes between the heaters 67 and therefore is not heated are not mixed with each other. The circuit board 61 on the transfer path 62 is eventually hit by the gas flows 70, 71 in different states of temperatures and velocities, thus failing to satisfy the reflow condition. An object of the present invention is to provide a reflow apparatus and method which can send the gas flow of uniform temperature and uniform velocity to a circuit board on a transfer path. SUMMARY OF THE INVENTION In accomplishing these and other objects, according to one aspect of the present invention, there is provided a reflow apparatus in which hot gas flow is fed to a circuit board to solder the circuit board while the circuit board to which a cream solder has been supplied beforehand is carried into a plurality of sections within a reflow furnace along a transfer path, the reflow apparatus comprising a heating section which comprises a fan for sending the gas flow, a heating device for heating gas sent out from the fan, and a circulating gas path for collecting and raising the gas flow sent out from the fan to the heating device and dropping down the raised gas flow towards the circuit board on the transfer path from an upper side of the heating section, characterized in that the heating device is arranged at one lateral side of the transfer path. In accordance to a further aspect of the present invention, there is also provided a reflow method for feeding hot gas flow to a circuit board to solder the circuit board while the circuit board to which a cream solder has been supplied beforehand is carried into a plurality of sections within a reflow furnace along a transfer path, the method comprising, in a heating section, steps of sending the gas flow by a fan, heating gas sent out from the fan by a heating device, and collecting and raising the gas flow sent out from the fan to the heating device and dropping down the raised gas flow towards the circuit board on the transfer path from an upper side of the heating section in a circulating gas path, characterized in that in the heating step the gas is sent out from the fan by a heating device which is arranged at one lateral side of the transfer path. Further advantageous embodiments are defined in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS These and other objects and features of the present invention will become clear from the following description taken in conjunction with the preferred embodiments thereof with reference to the accompanying drawings, in which: Fig. 1 is a perspective view, in partial section, of a heating unit of a reflow apparatus according to one embodiment of the present invention; Fig. 2 is a perspective view of the total reflow apparatus when a lid is opened; Fig. 3 is a schematic side sectional view showing the flow of the gas in the heating unit of the reflow apparatus ; Fig. 4 is a perspective view of structure to remove flux at an entrance and an exit of the reflow apparatus; Fig. 5 is a perspective view of structure to remove flux at the entrance of the reflow apparatus; Fig. 6 is a perspective view of structure to remove flux in the heating unit of the reflow apparatus; Fig. 7 is a perspective view of structure to remove flux of a cooling section of the reflow apparatus; Fig. 8 is a perspective view of structure to remove flux in the cooling section of the reflow apparatus; Fig. 9 is a perspective view of structure to remove flux in the cooling section of the reflow apparatus; Fig. 10 is a perspective view of structure to remove flux of a gas sucking section of the reflow apparatus; Fig. 11 is a schematic side sectional view of a heating unit of a reflow apparatus according to a further embodiment of the present invention; Fig. 12 is a schematic side sectional view of a heating unit of a reflow apparatus according to a further embodiment of the present invention; Figs. 13 and 14 are a perspective view and a sectional view of sliding structure of the straightening plate; Fig. 15 is a perspective view of a hollow part of the reflow apparatus and the vicinity thereof; Fig. 16 is a perspective view of an opening at the boundary of sections of the reflow apparatus and the vicinity thereof; Fig. 17 is an enlarged view of a flux reservoir in Fig. 6; Fig. 18 is a perspective view of a part of the reflow apparatus; Fig. 19 is a front view schematically showing the vicinity of a transfer path of the reflow apparatus; Fig. 20 is a perspective view of a part to explain the operation of the reflow apparatus; Fig. 21 is a diagram of the concentration of oxygen when a circuit board is transferred in the reflow apparatus; Fig. 22 is a diagram of the concentration of oxygen when the circuit board is transferred in a conventional reflow apparatus without having a pseudo board plate; Fig. 23 is a diagram of the correlation between the concentration of oxygen and the wettability of solder; Fig. 24 is a perspective view of the heating unit and a resistance section of the reflow apparatus; and Fig. 25 is a sectional view of a conventional reflow apparatus. DETAILED DESCRIPTION OF THE EMBODIMENTS Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals throughout the accompanying drawings. A preferred embodiment of the present invention will be described with reference to the accompanying drawings hereinbelow. As indicated in Fig. 2, there are arranged within a reflow furnace 1 along a transfer path of circuit boards 2 (with reference to Fig. 1) (path in a transferring direction (A) of circuit boards): an entrance resistance section 3, a first preheating section 4, a second preheating section 5, a third preheating section 6, a first reflow section 7, a second reflow section 8, a cooling section 9, and an exit resistance section 10 seen from the upstream side of the path. Each section is formed in a unit and filled with nitrogen gas. The preheating sections 4, 5, 6 and reflow sections 7, 8 are constituted of heating units (U) of the similar constitution shown in Fig. 1. The internal gas flow is circulated inside the heating unit (U) by a sirocco fan 11 placed in the lower part of the heating unit (U) for circulating hot gas. At the same time, the internal gas flow is circulated in a cooling unit constituting the cooling section 9 by a propeller fan 12 which is arranged in the upper part of the cooling unit to circulate cold gas. The lower right of Figs. 1 and 2 is the front side of the apparatus in the description below. In each heating unit (U), as indicated in Figs. 1 and 3, there are a lower path 13 extending rearward and a rear path 14 extending upward from behind the sirocco fan 11 in a box-shaped space defined by an inner wall surface (Ua) of the unit (U). A suction port 13a is formed in the lower path 13 above the sirocco fan 11. A heater 15 is provided in the rear path 14 to heat the circulating gas flow. At the same time, a plurality of straightening plates 16 and a blow-down nozzle 17 are placed in the upper part of the heating unit (U) so as to guide and blow out the gas flow heated by the heater 15 towards the transfer path. In other words, the inner wall surface (Ua) forming the box-shaped space and the lower path 13 and the rear path 14 constitute a circulating gas path. In the circulating gas path, the gas flow (B) sent rearward through the lower path 13 from the sirocco fan 11 ascends through the rear path 14 frontward and at the same time, falls down to be sucked by the sirocco fan 11 again. The straightening plate 16 is extended frontward approximately horizontally and bent downward at the front part thereof in cross section. The straightening plate 16 is extended along the transferring direction (A) of circuit boards. There are a plurality of straightening plates 16 (two in the embodiment in Fig. 3) arranged in the backward-and-forward direction. As shown in Figs. 13 and 14, projections 16a of the straightening plate 16 are fitted in elongated holes 16b formed in the upper surface part (Uc) of the inner wall surface (Ua) of the heating unit (U), so that the straightening plate 16 is supported to be slidable back and forth. In the embodiment, as shown in Fig. 3, the straightening plates 16 are arranged so that the distance (L1) between a guide plate 18 in the upper part closer to the rear side of the heating unit (U) and the rear straightening plate 16 is larger than the distance (L2) between the front and rear straightening plates 16 and, this distance (L2) is larger than the distance (L3) in the backward-and-forward direction between the front straightening plate 16 and a front surface part (Ub) of the inner wall surface (Ua). The inner wall surface (Ua) of the heating unit (U) stands beside the straightening plate 16 to separate and prevent the hot gas flow from moving to the adjacent section. The straightening plates 16 are set approximately at the same height with the same cross section in the embodiment. Referring to Figs. 1, 2, and 16, reference numerals 123A, 123B denote a pair of transfer guide rails constituting the transfer path, with chain conveyors 124 arranged thereinside. The transfer guide rail 123A at the front side is fixed at a predetermined position, while the transfer guide rail 123B at the rear side is made slidable in the lateral direction approximately orthogonal to the transferring direction (A), namely, in the widthwise direction of the transferred circuit board 2. Therefore, the transfer guide rails 123A and 123B are adapted to treat the circuit boards 2 of various kinds of width. An opening 125 is formed at the boundary of the sections. The transfer guide rails 123A and 123B penetrate the opening 125. The blow-down nozzle 17 is constituted of a plurality of bent plates 19 aligned in the transferring direction (A). The plate 19 has an inverse U-shaped cross section and is extended in the backward-and-forward direction as is clearly understood from Fig. 1. Slit openings are formed between the adjacent bent plates 19. The blow-down nozzle 17 shoots out the hot gas flow of gas from above towards the transfer path at high speeds, and turns back the gas flow which is inclined to flow in parallel to the transferring direction (A). A notched part 25a is formed at the position of a supporting plate 25, which supports the front and rear ends of the plate 19, corresponding to the inner surface of the bent plate 19. Moreover, a hollow part 126 having a large sectional area to the transferring direction (A) and formed of a box-shaped frame 126a is provided between the sections. The gas flow (C) running from the section to the adjacent section enters the hollow part 126. As is clearly shown in Fig. 16, the transfer guide rail 123B at the rear side which is slidable in the widthwise direction of the circuit board 2 is provided with a shutter mechanism 127. The shutter mechanism 127 is comprised of a main body 128 having strips of plates coupled one another in the lateral direction in the bendable fashion, a mounting part 130 secured at the end of the main body 128 to the transfer guide rail 123B via bolts 129, and a case frame 131 located at the rear surface of each section for accommodating the main body 128 from back and forth. A fixed shutter plate 132 is set closer to the front side of the apparatus than the opening 125 of the front transfer guide rail 123A. In the above-described structure, as shown in Fig. 15, while the amount of the gas flow (C) flowing along the transfer path is reduced by the lower surface of the blow-down nozzle 17, the gas flow enters the hollow part 126 through the opening 125 at the boundary of the sections. At this time, since the hollow part 126 is a space of a large sectional area, the pressure is lost because of the sudden increase of the sectional area of the path, and consequently the speed of the gas flow (C) from the section is decreased by the hollow part 126. As a result, the flowing-in/out amount of the gas flow between the adjacent sections is restricted to be minimum, so that the low concentration of oxygen and the appropriate temperature in each section can be maintained stably. Further, as shown in Fig. 16, since the unnecessary part of the opening 125 for the circuit board 2 at the boundary of the sections is closed by the shutter mechanism 127, the area of the opening 125 is limited to the necessary minimum, thereby stably securing the low concentration of oxygen and proper temperature in each section. In the above embodiment, the shutter mechanism 127 is installed in the case where only one transfer guide rail 123B is made movable in the widthwise direction of the circuit boards. However, the shutter mechanism 127 can be also easily installed for each of the pair of the transfer guide rails 123A and 123B when both of the transfer guide rails are movable. Moreover, the shutter mechanism 127 cannot be mounted to the transfer guide rail, but a mechanism to press the shutter mechanism 127 to the transfer guide rail can be provided to move the shutter mechanism 127 integrally with the transfer guide rail. Needless to say, the present invention is applicable to a reflow apparatus using the other inert gas, e.g., argon gas or the like than nitrogen gas. According to the present invention as described hereinabove, since the hollow part is provided between the adjacent sections to obtain the pressure loss from the sudden increase of the sectional area of the path, the speed of the gas flow from the section can be decreased by the hollow part, and the amount of the gas flow entering and coming out of the adjacent section can be restricted to be minimum, whereby the low concentration of oxygen and the proper temperature in each section can be ensured stably. In addition, at least one of the pair of the transfer guide rails is made movable in the lateral direction orthogonal to the transfer path, and the shutter mechanism is provided which moves along with the movable transfer guide rail thereby to shut the part of the opening at the boundary of sections except for the transfer path. Accordingly, the area of the opening between the adjacent sections is restricted to be minimum, and the amount of the gas flow entering and coming out of the adjacent section is restricted to be minimum by this arrangement, whereby the low concentration of oxygen and the proper temperature in each section can be secured stably. The pseudo board plate 20 is placed in parallel to the transferring surface of the circuit board 2 below the transfer path in each heating unit (U) of the preheating sections 4, 5, 6, as is clearly seen in Figs. 1 and 18. The pseudo board plate 20 is approximately of the same width as the maximum width of the circuit board 2, having a plurality of plate-like parts 21 on the upper surface thereof which stand every predetermined distance to the transferring direction (A) of the circuit boards 2 and extend in the lateral direction approximately orthogonal to the transferring direction (A) of the circuit boards 2 (in the widthwise direction of the circuit board 2). As is shown in Fig. 19, the pseudo board plate 20 is separated a distance (L) corresponding to the mounting space of components at the lower surface of the circuit board 2 from the upper end of the plate-like parts 21. At the same time, the pitch P 3 between the plate-like parts 21 is shifted half a pitch from the pitch P 4 between the bent plates 19 of the blow-down nozzles 17, so that the gas flow jetted out from the slit between the bent plates 19 downward can be guided well to the interval of the plate-like parts 21. The standing height of the plate-like parts 21 is set to be about 20mm in the embodiment. Moreover, a blow-down nozzle (not shown) is provided in the heating unit (U) of each of the reflow sections 7, 8 to heat the lower surface of the transferred circuit board 2, without the pseudo board plate 20 provided. In the above-described structure, as shown in Figs. 18 and 20, the gas flow (B) running to the transfer path (D) hits the circuit board 2 and the pseudo board plate 20 when the circuit board 2 is on the transfer path (D), and in consequence the gas flow (B) is diverged in the widthwise direction of the circuit board 2 to run along the circuit board 2 and the rear surfaces from the front surfaces of the pseudo board plate 20. Even when the circuit board 2 is not present in the transfer path (D), the gas flow (B) is allowed to run along the rear surfaces from the front surfaces of the pseudo board plate 20. Accordingly, irrespective of the presence/absence of the circuit board 2, the running direction of the gas flow (B) can be made constant. Because of the standing plate-like parts 21 extended in the lateral direction approximately orthogonal to the transferring direction (A) of the circuit boards 2 in the pseudo board plate 20, the gas flow (B) is guided positively in the lateral direction approximately orthogonal to the transferring direction (A) of the circuit boards 2 (widthwise direction of the circuit board 2), whereby the flow towards the transferring direction (A), namely, the flow of the gas between the units or through the opening to the outside can be restricted to be minimum. Accordingly, since the direction of the gas flow (B) is made constant and the flow of the gas between the units or between the unit and the outside can be suppressed to be minimum, the low concentration of oxygen and the atmosphere of the optimum temperature can be stably secured. Figs. 21 and 22 indicate comparative examples, in which (T1) is the time when the circuit board 2 is carried into the apparatus and (T2) is the time when the circuit board 2 is carried out from the apparatus. In the case where the pseudo board plate 20 is not provided, as is apparent from Fig. 22, the concentration of oxygen is changed to 1000ppm after the circuit board 2 is carried into the apparatus although the concentration of oxygen is 100ppm at the time (T1) when the circuit board 2 is carried in. On the other hand, when the pseudo board plate 20 is set, the concentration of oxygen is maintained at 100ppm even after the circuit board 2 is carried into the apparatus, as is shown in Fig. 21. Fig. 23 is a graph showing the wettability related to the concentration of oxygen. As indicated in Fig. 23, the wettability is best when the concentration of oxygen is about 100ppm. As the concentration of oxygen is increased, the wettability is decreased. In other words, as the concentration of oxygen is kept favorably at 100ppm or so, the generation of inferior parts caused by the solder bridge or the generation of solder balls which were brought about due to the deterioration of the wettability in the prior art can be prevented well. As shown in Fig. 24, a plurality of plate-like parts 22 are provided also at the entrance and exit resistance sections 3, 10. The plate-like parts 22 are extended in the lateral direction approximately orthogonal to the transferring direction (A) of the circuit boards 2 above and below the transfer path (D). Therefore, the gas is prohibited from flowing out from the inside of the reflow furnace 1 and the gas is prevented from entering from outside by the plate-like parts 22. According to the present invention as described hereinabove, since the pseudo board plate is arranged parallel to the transferring surface of the circuit board to guide the gas flow running towards the transfer path in a fixed direction, the running direction of the gas flow can be made constant irrespective of the presence or absence of the circuit board, and accordingly, the low concentration of oxygen and the atmosphere of the optimum temperature can be stably secured. Moreover, the pseudo board plate is provided with plate-like parts standing and extending in the lateral direction approximately orthogonal to the transferring direction of the circuit board. Accordingly, the gas flow between the sections and between the section and the outside can be suppressed to be minimum, thus further positively ensuring the state of the low concentration of oxygen and the atmosphere of the optimum temperature. Meanwhile, a plurality of measures are taken to remove flux in the reflow furnace 1. First, such an arrangement is designed where the circuit board 2 is carried in and out that the air entering along with the circuit board 2 is discharged outside through an exhaust duct 30 shown in Figs. 2 and 4. A metal mesh 31 is provided at a suction port of the exhaust duct 30. The flux dropping from the inclined lower surface of a frame body 32 with the metal mesh 31 is received by a pan 33. At the same time, another frame body 34 shown in Fig. 5 is provided below an entrance tunnel which is an entrance to the reflow furnace 1 to collect the flux falling from the circuit board 2. The dropping flux from the frame body 34 is received by a receiver container 35. As indicated in Fig. 6, there is provided a wall receiver 36 at the wall surface in front of the upper edge of the rear path 14, etc. in each heating unit (U) so as to remove the flux solidified at the wall surface within the reflow furnace 1. Moreover, a receiver 37 is placed below the heater 15. Upon necessities, a catalyst 38 is set above the heater 15, as shown in Fig. 7, to reduce the flux. Further, as in Fig. 6, metal meshes 39 for removing the flux are arranged respectively in front of and in the rear of the pseudo board plate 20, and a flux reservoir 40 is formed in the upper part of each bent plate 19 of the blow-down nozzle 17 in the third preheating section 6. In Fig. 8, a pan 42 is provided below a cooling fin 41 of the cooling section 9 to receive the flux dropping out from the cooling fin 41. Also a filter of metal mesh 43 below the cooling section 9 removes the flux. It can be so arranged as shown in Fig. 9 that a cooling fin 44 is disposed above the cooling section 9, with a pan 45 and a double-layer filter 46 therebelow. The filter 46 can be formed of three or more layers. In the reflow furnace 1, a temperature sensor and a gas suction port (not shown) are provided in the unit constituting each of the first preheating section 4, second preheating section 5, third preheating section 6, first reflow section 7, second reflow section 8, and cooling section 9. After the flux is removed from the gas sucked through the suction port by a wool-glass filter 51, a mesh filter 52, and an activated carbon filter 53, etc. as shown in Fig. 10, the concentration of oxygen is measured by an oxygen concentration analyzer 50. The state and temperature of the hot gas flow in the reflow furnace 1 are controlled based on the data of the temperature and oxygen concentration of each section, thereby to feedback and control the oxygen concentration and temperature of each section within a predetermined range. In the present reflow furnace 1, the oxygen concentration of the preheating sections 4, 5, and 6 is controlled to be approximately 400ppm, and that of the reflow sections 7 and 8 is controlled to be about 100ppm. A predetermined amount of nitrogen gas is mixed with a predetermined amount of air through feedback control of the feeding amount thereof, and then the mixed gas is supplied to the reflow furnace 1 by 200ℓ per min. Referring to Fig. 1, reference numeral 47 is an injection nozzle of nitrogen gas mixed with air to blow gas with the low concentration of oxygen, and reference numeral 48 indicates an exhaust duct. The mixed gas is injected at all times or at the time of reflow and, exhausted when the reflow is finished, etc. Moreover, reference numeral 55 in Fig. 2 shows a lid body to cover the upper surface of each unit. In the above-described constitution, as shown in Figs. 1 and 3, the hot gas flow (B) from the rear path 14 is moved forward as shown in Fig. 1 along the upper surface (Uc) of the inner wall surface (Ua). During this movement, while the hot gas flow is dispersed in the forward-and-backward direction of the straightening plates 16, the gas flow descends downward. Since the distance (L1) between the guide plate 18 set in the upper part closer to the rear side of the heating unit (U) and the rear straightening plate 16 is larger than the distance (L2) between the front and rear straightening plates 16, and moreover, the distance (L2) is larger than the distance (L3) between the front straightening plate 16 and the front surface part (Ub) of the inner wall surface (Ua), the horizontal surface where the gas flow falls at the straightening plates 16 is divided into smaller areas towards the front side by the straightening plates 16. Therefore, although the gas flow would descend more at the front side by inertia without the straightening plates 16, the hot gas flow is actually uniformly dispersed in the backward-and-forward direction owing to the presence of the straightening plates 16. Moreover, the hot gas flow is dispersed in the transferring direction (A) as well by the blow-down nozzle 17 and jetted out towards the circuit board 2 on the transfer path. Accordingly, the hot gas flow of uniform velocity can be shot to the total surface of the circuit board 2 in the vertical direction, thus achieving favorable preheating and reflow. Since the circulating gas path is formed in each unit to move the hot gas flow upward fully from the rear side and to drop from the front side, the gas flows (B) are stirred when passing through the circulating path, so that the temperature and velocity of the gas flows are turned uniform. Accordingly, the circuit board 2 on the transfer path can be heated well by the gas flows having the uniform temperature and velocity. Moreover, since the gas flows are jetted out to the circuit board 2 in the vertical direction by the straightening plates 16 and blow-down nozzle 17, the gas flows in the transferring direction (A) can be restricted to minimum and the direction of the internal gas flow can be made constant. The low concentration of oxygen and the atmosphere of the optimum temperature can be secured in each unit or each section. Moreover, even when the hot gas flow blown out to the circuit board 2 is reflected to hit the rear surface of the bent plates 19 of the blow-down nozzle 17, the reflected flow is discharged out through the notched parts 25a of the bracket plates 25 in front of and in the rear of the plates 19. Therefore, it is prevented that the hot gas flow remains at the rear surface side of the blow-down nozzle 17. Fig. 11 shows a modification of the embodiment of the present invention. In the modification of Fig. 11, a straightening plate 57 is formed of a plate extending only in the up-and-down direction. A plurality of straightening plates 57 are arranged every predetermined distance (P 1 ) in the forward-and-backward direction. The straightening plates 57 are so arranged that one disposed at the side of the lower stream in the lateral direction of the hot gas flow, namely, at the front side has its upper end extended more by the distance (P 2 ) than the rear straightening plate 57. Because of such arrangement of the straightening plates 57 as above, the hot gas flow inclined to run from the upper part of the rear path 14 to the front side is dispersed uniformly in the up-and-down direction when the hot gas flow is guided downward. Therefore, the hot gas flow of the uniform velocity is shot to the circuit board 2 on the transfer path, thereby realizing favorable preheating and reflow. It is to be noted that if the length of the straightening plates 57 is rendered the same in the up-and-down direction, and the straightening plates at the more front side can be placed at a higher position as the straightening plates are shifted only in the up-and-down direction. Fig. 12 shows another modification of the embodiment. In this modification, the length of the straightening plates 57 is the same and the upper surface (Uc) of the inner wall surface (Ua) is inclined (Uc) so that the distance between the upper surface (Uc) and the upper end of the rear straightening plate 57 is larger than the distance between the upper surface (Uc) and the upper end of the front straightening plate 57. As a result, the same operation and effects can be obtained as the foregoing modification. In the embodiment, nitrogen gas is used as the inert gas. It is needless to say that the present invention is easily applicable to a reflow furnace which shoots out the other inert gas or which performs the reflow in the air. As described hereinabove, according to the present invention, the circulating gas path is formed to move the gas flow up from one side of the heating section and to drop from the other side of the heating section. Therefore, even when the gas flows heated in different manners by the heating means are discharged, the gas flows are stirred through the circulating path, so that the temperature and velocity of the gas flows become uniform. The circuit board on the transfer path can be heated well by the gas flows of the uniform temperature and velocity. Moreover, it is prevented, for example, that the gas flows ascending from both sides meet at the center to be disturbed each other. Accordingly, the directions of the internal gas flow in the heating sections within the reflow furnace can be made constant, with the atmosphere of the optimum temperature secured. Since a plurality of straightening plates are arranged above the transfer path to guide the hot gas flow running in the lateral direction down to the circuit board on the transfer path, the running direction of the internal gas flow, particularly, the running direction and running speed of the internal gas flow in the vicinity of the transfer path can be made constant, and the temperature and velocity of the gas flow hitting the circuit board can be made uniform. Further, as the straightening plates are slidable in the lateral direction orthogonal to the transferring direction of circuit boards, the amount of the hot gas flow in the lateral direction orthogonal to the transferring direction can be adjusted easily. Since the distance between the adjacent straightening plates to the lateral direction orthogonal to the transferring direction of circuit boards is arranged to be smaller than that between the straightening plate and the guide wall surface which guides down the hot gas flow towards the lower stream of the lateral running direction of the hot gas flow, the amount of the hot gas flow to the lateral direction orthogonal to the transferring direction can be made uniform. Moreover, when the straightening plate disposed at the much lower stream of the lateral running direction of the hot gas flow is arranged at the upper side of the circulating gas path, it is possible to turn the amount of the hot gas flow uniform, whereby the temperature and velocity of the hot gas flow jetted out to the circuit board can be uniform. The blow-down nozzle is constituted of plates aligned in a plurality of rows every predetermined distance in the transferring direction of circuit boards. The plate has two edges bent downward in cross section. The blow-down nozzle is set below the straightening plates and the gas flow is blown out to the circuit board from slit openings formed between the plates of the blow-down nozzle. Therefore, the hot gas flow can be jetted to the circuit board while the hot gas flow is favorably dispersed in the transferring direction. Since the notched part is formed to discharge the gas flow entering the rear side of the blow-down nozzle outside, the hot gas flow is prevented from being left at the rear side of the blow-down nozzle, thereby more easily ensuring the low concentration of oxygen and the atmosphere of the optimum temperature. Since the gas flow is sent from only one side of the fan as shown in Fig. 3, the efficiency is better than a case where the gas flow is sent from both sides of the fan.

Claims: A reflow apparatus in which hot gas flow is fed to a circuit board (2) to solder the circuit board (2) while the circuit board (2) to which a cream solder has been supplied beforehand is carried into a plurality of sections within a reflow furnace (1) along a transfer path (A, D), the reflow apparatus comprising a heating section (U) which comprises: a fan (11) for sending the gas flow (B); a heating device (15) for heating gas sent out from the fan (11), and a circulating gas path (13, 14, B) for collecting and raising the gas flow sent out from the fan (11) to the heating device (15) and dropping down the raised gas flow towards the circuit board (2) on the transfer path from an upper side of the heating section (U); characterized in that the heating device (15) is arranged at one lateral side of the transfer path (A D). The reflow apparatus as claimed in claim 1, wherein the heating section (U) further comprises a plurality of straightening plate members (16) arranged above the transfer path (D) to form a plurality of openings so as to guide down the hot gas flow running in a lateral direction orthogonal to a transferring direction (A) of the circuit boards (2) towards the circuit board (2) on the transfer path (D) through the openings. The reflow apparatus as claimed in claim 2, wherein each straightening plate member (16) is attached to an upper part of the heating section (U) so as to be slidable in the lateral direction orthogonal to the transferring direction (A) of the circuit boards (2). The reflow apparatus as claimed in claim 2, wherein the straightening plate members (16) are so arranged that a distance of the opening at a front side (Ub) of the heating section (U) in the lateral direction orthogonal to the transferring direction (A) of the circuit boards (2) is smaller than that of the opening at a rear side of the heating section (U) so as to uniformly guide down the hot gas flow. The reflow apparatus as claimed in claim 2, wherein the straightening plate members (16) with the same vertical length are so arranged that distances between upper ends of the straightening plate members (16) and an upper wall (Uc) of the heating section (U) gradually become smaller as directing from a rear part to a front part of the heating section (U). The reflow apparatus as claimed in claim 2, wherein an upper wall (Uc) of the heating section (U) is inclined from a rear side to a front side of the heating section (U) so that distances between upper ends of the straightening plate members (16) and an upper wall (Uc) of the heating section (U) gradually become smaller as directing from a rear part to a front part of the heating section (U). The reflow apparatus as claimed in claim 2, wherein a blow-down nozzle (17) having a length equal to or more than a length of the circuit board (2) in the transferring direction (A) of the circuit boards (2) is formed of plate members (19) each having both edges bent downward in cross section and aligned in a plurality of rows every predetermined distance in the transferring direction of the circuit boards (2), which is arranged below the straightening plate members (16), so that the gas flow (B, C) is blown out to the circuit board (2) through a slit opening formed between the plate members (19) of the blow-down nozzle (17). The reflow apparatus as claimed in claim 1, further comprising a catalyst (38) arranged at a downstream side of the heating device (U) for removing flux from the gas flow. The reflow apparatus as claimed in claim 7, wherein the blow-down nozzle (17) has a flux receiving member (40) of M-shaped sectional structure at an upper portion thereof for removing flux from the gas flow (B, C). The reflow apparatus as claimed in claim 1, further comprising a hollow part (126), arranged between the sections, for suddenly increasing of a sectional area of the path to cause pressure loss by the part to reduce speed of the gas flow from the section. The reflow apparatus as claimed in claim 1 or 10, comprising: a pair of transfer guide rail members (123A,123B) arranged so as to hold the path therebetween at least one of which is movable in a lateral direction orthogonal to the transfer path (D); and a shutter mechanism (127) provided to move integrally with the movable transfer guide rail member (123A, 123B) to shut a part of an opening, except for the transfer path, formed at a boundary of the sections through which the circuit board (2) passes. A reflow method for feeding hot gas flow to a circuit board (2) to solder the circuit board (2) while the circuit board (2) to which a cream solder has been supplied beforehand is carried into a plurality of sections within a reflow furnace (1) along a transfer path (A, D), the method comprising, in a heating section (U), steps of: sending the gas flow (B) by a fan (11); heating gas sent out from the fan (11) by a heating device (15); and collecting and raising the gas flow sent out from the fan (11) to the heating device (15) and dropping down the raised gas flow towards the circuit board (2) on the transfer path (A, D) from an upper side of the heating section (U) in a circulating gas path; characterized in that in the heating step the gas is sent out from the fan (11) by a heating device (15) which is arranged at one lateral side of the transfer path (A, D). The reflow method as claimed in claim 12, further comprising a step of suddenly increasing of a sectional area of the path by a hollow part (126) arranged between the sections and then causing pressure loss by the part to reduce speed of the gas flow (B, C) from the section. The reflow method as claimed in claim 12 or 13, further comprising steps of shutting a part of an opening, except for the transfer path (D), formed at a boundary of the sections through which the circuit board passes, by a shutter mechanism (127) provided to move integrally with a movable member of a pair of transfer guide rail members (123A,123B) arranged so as to hold the path therebetween, the movable member being movable in a lateral direction orthogonal to the transfer path (D).

Inventors: ANDO MANABU, HAMASAKI KURAYASU, ISHIMOTO KAZUMI, KUWABARA KIMIHITO, MIMURA TOSHINORI, NAKAMURA YOUICHI, NAKANO KENICHI, TANIGUCHI MASAHIRO, ANDO, MANABU, HAMASAKI, KURAYASU, ISHIMOTO, KAZUMI, KUWABARA, KIMIHITO, MIMURA, TOSHINORI, NAKAMURA, YOUICHI, NAKANO, KENICHI, TANIGUCHI, MASAHIRO
Applicants: MATSUSHITA ELECTRIC IND CO LTD, MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD.
Application year: 1993
Main classification: B23K1
IPC codes: B23K1