Patent Publication Number: US-2022226919-A1

Title: Soldering iron including temperature profiling and method of use

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-in-Part of U.S. patent application Ser. No. 17/150,817 filed Jan. 15, 2021, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The disclosed invention relates generally to manufacturing, repair and rework of printed circuit boards (PCBs) using soldering, and more particularly to a soldering iron with temperature profiling. 
     BACKGROUND 
     Two existing hand soldering systems that exist are adjustable tip temperature soldering systems, and fixed tip temperature soldering systems. Once the tip temperature is set for the soldering process in either of these systems, the tip temperature does not change during the soldering process. With smaller and smaller product package sizes, thermal shock, micro-cracking, etc. causes products to fail prematurely. Further, some applications require a printed circuit board (PCB) to be pre-heated to a preset temperature before physically contacting the tip to the component. 
     SUMMARY OF THE INVENTION 
     An aspect of the invention involves a soldering iron system including temperature profiling, allowing an operator to set multiple tip temperatures at fixed times or self-adjustable times during a solder event. 
     Another aspect of the invention involves a soldering iron with temperature profiling, comprising: a hand piece or a robot arm including a soldering tip; a processor configured to: provide temperature profiling where the soldering tip is one or more of the following during a soldering event: provided at a fixed tip temperature ramp rate during the soldering event; and provided at an adjustable tip temperature ramp rate during the soldering event. 
     One or more implementations of the aspect described immediately above include one or more of the following: the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at fixed times during the soldering event; the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at self-adjusting times during the soldering event; the soldering iron further includes a power supply unit; the soldering iron further includes a stand; the processor is in one or more of the stand, the power supply, and the hand piece or robot arm; the soldering iron includes a hand piece, and the handpiece includes the solder tip, a resistance temperature detector (RTD), a coil to generate a magnetic field, and a magnetic shield; the handpiece includes a ceramic insulator; the handpiece includes a shaft, shrink tube, and a connector; the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at fixed startup, soak, and reflow times during the soldering event; the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at self-adjusting startup, soak, and reflow times during the solder event; and/or the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at both of the following during the soldering event: one or more fixed startup, soak, and reflow times; and self-adjusting startup, soak, and reflow times. 
     Another aspect of the invention involves a computer implemented method for temperature profiling with a soldering iron comprising a hand piece or a robot arm including a soldering tip, where one or more processors are programmed to perform steps comprising: providing temperature profiling where the soldering tip is one or more of the following during a soldering event: provided at a fixed tip temperature ramp rate during the soldering event; and provided at an adjustable tip temperature ramp rate during the soldering event. 
     One or more implementations of the aspect described immediately above include one or more of the following: the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at fixed times during the soldering event; the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at self-adjusting times during the soldering event; providing temperature profiling where the soldering tip is provided at multiple tip temperatures at fixed startup, soak, and reflow times during the soldering event; providing temperature profiling where the soldering tip is provided at multiple tip temperatures at self-adjusting startup, soak, and reflow times during the solder event; providing temperature profiling where the soldering tip is provided at multiple tip temperatures at both of the following during the soldering event: one or more fixed startup, soak, and reflow times; and self-adjusting startup, soak, and reflow times. 
     A further aspect of the invention involves a non-transitory computer readable medium having stored thereon one or more sequences of instructions for causing one or more processors to perform the steps for temperature profiling with a soldering iron comprising a hand piece or a robot arm including a soldering tip, the steps comprising: providing temperature profiling where the soldering tip is one or more of the following during a soldering event: provided at a fixed tip temperature ramp rate during the soldering event; and provided at an adjustable tip temperature ramp rate during the soldering event. 
     One or more implementations of the aspect described immediately above include one or more of the following: the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at fixed times during the soldering event; the processor is configured to provide temperature profiling where the soldering tip is provided at multiple tip temperatures at self-adjusting times during the soldering event; providing temperature profiling where the soldering tip is provided at multiple tip temperatures at fixed startup, soak, and reflow times during the soldering event; providing temperature profiling where the soldering tip is provided at multiple tip temperatures at self-adjusting startup, soak, and reflow times during the solder event; providing temperature profiling where the soldering tip is provided at multiple tip temperatures at both of the following during the soldering event: one or more fixed startup, soak, and reflow times; and self-adjusting startup, soak, and reflow times. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  depicts an embodiment of a handheld soldering iron system including temperature profiling. 
         FIG. 2  is a perspective view of an embodiment of a variety of components of a soldering iron of the handheld soldering iron system including temperature profiling of  FIG. 1A . 
         FIG. 3  is an additional perspective view of the soldering iron of  FIG. 2  showing a variety of components of the soldering iron. 
         FIG. 4  is another perspective view of the soldering iron of  FIG. 2  showing a variety of components of the soldering iron. 
         FIG. 5  is a further perspective view of the soldering iron of  FIG. 2  showing a variety of components of the soldering iron. 
         FIG. 6  is a still further perspective view of the soldering iron of  FIG. 2  showing a variety of components of the soldering iron. 
         FIG. 7  is a block diagram illustrating an example wired or wireless processor enabled device that may be used in connection with the embodiment(s) described herein. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIGS. 1-7 , an embodiment of a handheld soldering iron system  100  including temperature profiling will be described. The handheld soldering iron system includes a processor, such as a microprocessor or controller, memory, input/output circuitry and other necessary electronic circuitry to perform the temperature profiling shown and/or described herein. 
       FIG. 1  depicts the handheld soldering iron system  100 . As shown, the handheld soldering iron system includes a power supply unit  110  including a display  120  such as an LCD display, and various inputs  125 . The soldering iron system  100  further includes a hand piece  130  coupled to the power supply unit  110  and a (work) stand  140  that accommodates the hand piece  130 . The hand piece  130  receives power from the power supply unit  110  and heats a soldering tip attached to or located in a soldering cartridge to perform the soldering on a work piece. 
     In one or more embodiments, the power supply unit  110  and/or the hand piece  130  includes a microprocessor, memory, input/output circuitry and other necessary electronic circuitry to perform various processes such as those described herein. One skilled in the art would recognize that the microprocessor(s) (or the controller(s)) may be placed in one or more of the power supply unit  110 , in the hand piece  130 , or a stand  140  of the soldering system  100 . Communication with external devices, such as a local computer, a remote server, a robot for performing the soldering, a printer and the like, may be performed at the work stand  140  by wired and/or wireless connections, using the known wired and/or wireless interfaces and protocols. 
     The hand piece  130  includes a solder tip or heater tip  150 , a resistance temperature detector (RTD)  160 , a coil  170  to generate a magnetic field, a magnetic shield  170 , a ceramic insulator  180 , a front shaft  190 , shrink tube  200 ,  210 , a connector  220  for both electrical and mechanical connections (e.g., to a hand-piece or robot arm for efficient, quick-release operation), and a rear shaft  230 . 
     In one or more embodiments, the microprocessor/processor and the associated circuits provide temperature profiling, allowing the operator to set multiple tip temperatures at fixed times and/or self-adjusting times during a solder event, and allowing the operator to set a fixed or adjustable tip temperature ramp rate during a solder event. 
     In an exemplary first or fixed-time temperature profile, for a solder event, during startup or Zone  1 , the solder tip  150  is set to a temperature of 120 C for 2 seconds, then during soak or Zone  2 , the solder tip  150  is set to a temperature of 180 C for 2 seconds, then during reflow or Zone  3 , the solder tip  150  is set to a temperature of 250 C for 1.5 seconds, and finally during cooling or Zone  4 , during which the solder tip  150  does not have physical contact to the joint, the solder tip  150  is allowed to naturally cool down to room temperature. 
     In an exemplary second or adjustable-time temperature profile, for a solder event, during startup or Zone  1 , the solder tip  150  is ramped up for x seconds (as much time as it takes) to a temperature of 120 C, then during soak or Zone  2 , the solder tip  150  is ramped up for y seconds (as much time as it takes) to a temperature of 180 C, then during reflow or Zone  3 , the solder tip  150  is ramped up to a temperature of 250 C for z seconds (as much time as it takes), and finally during cooling or Zone  4 , during which the solder tip  150  does not have physical contact to the joint, the solder tip  150  is allowed to naturally cool down to room temperature. 
     In an exemplary third or combination fixed-time and adjustable-time temperature profile, for a solder event, during startup or Zone  1 , the solder tip  150  is set to 120 C for 1 second and then ramped up to a temperature of 120 C, then during soak or Zone  2 , the solder tip  150  is ramped up for x seconds (as much time as it takes) to a temperature of 180 C, then during reflow or Zone  3 , the solder tip  150  is set to 250 C for 2 seconds, and finally during cooling or Zone  4 , during which the solder tip  150  does not have physical contact to the joint, the solder tip  150  is allowed to naturally cool down to room temperature. 
       FIG. 7  is a block diagram illustrating an example wired or wireless system  550  that may be used in connection with various embodiments described herein. For example the system  550  may be used as or in conjunction with the microprocessor/processor/controller temperature profiling function(s) described herein. The system  550  can be a conventional personal computer, computer server, personal digital assistant, smart phone, tablet computer, or any other processor enabled device that is capable of wired or wireless data communication. Other computer systems and/or architectures may be also used, as will be clear to those skilled in the art. 
     The system  550  preferably includes one or more processors, such as processor  560 . Additional processors may be provided, such as an auxiliary processor to manage input/output, an auxiliary processor to perform floating point mathematical operations, a special-purpose microprocessor having an architecture suitable for fast execution of signal processing algorithms (e.g., digital signal processor), a slave processor subordinate to the main processing system (e.g., back-end processor), an additional microprocessor or controller for dual or multiple processor systems, or a coprocessor. Such auxiliary processors may be discrete processors or may be integrated with the processor  560 . 
     The processor  560  is preferably connected to a communication bus  555 . The communication bus  555  may include a data channel for facilitating information transfer between storage and other peripheral components of the system  550 . The communication bus  555  further may provide a set of signals used for communication with the processor  560 , including a data bus, address bus, and control bus (not shown). The communication bus  555  may comprise any standard or non-standard bus architecture such as, for example, bus architectures compliant with industry standard architecture (“ISA”), extended industry standard architecture (“EISA”), Micro Channel Architecture (“MCA”), peripheral component interconnect (“PCI”) local bus, or standards promulgated by the Institute of Electrical and Electronics Engineers (“IEEE”) including IEEE 488 general-purpose interface bus (“GPIB”), IEEE 696/S-100, and the like. 
     System  550  preferably includes a main memory  565  and may also include a secondary memory  570 . The main memory  565  provides storage of instructions and data for programs executing on the processor  560 . The main memory  565  is typically semiconductor-based memory such as dynamic random access memory (“DRAM”) and/or static random access memory (“SRAM”). Other semiconductor-based memory types include, for example, synchronous dynamic random access memory (“SDRAM”), Rambus dynamic random access memory (“RDRAM”), ferroelectric random access memory (“FRAM”), and the like, including read only memory (“ROM”). 
     The secondary memory  570  may optionally include an internal memory  575  and/or a removable medium  580 , for example a floppy disk drive, a magnetic tape drive, a compact disc (“CD”) drive, a digital versatile disc (“DVD”) drive, etc. The removable medium  580  is read from and/or written to in a well-known manner. Removable storage medium  580  may be, for example, a floppy disk, magnetic tape, CD, DVD, SD card, etc. 
     The removable storage medium  580  is a non-transitory computer readable medium having stored thereon computer executable code (i.e., software) and/or data. The computer software or data stored on the removable storage medium  580  is read into the system  550  for execution by the processor  560 . 
     In alternative embodiments, secondary memory  570  may include other similar means for allowing computer programs or other data or instructions to be loaded into the system  550 . Such means may include, for example, an external storage medium  595  and an interface  570 . Examples of external storage medium  595  may include an external hard disk drive or an external optical drive, or and external magneto-optical drive. 
     Other examples of secondary memory  570  may include semiconductor-based memory such as programmable read-only memory (“PROM”), erasable programmable read-only memory (“EPROM”), electrically erasable read-only memory (“EEPROM”), or flash memory (block oriented memory similar to EEPROM). Also included are any other removable storage media  580  and communication interface  590 , which allow software and data to be transferred from an external medium  595  to the system  550 . 
     System  550  may also include an input/output (“I/O”) interface  585 . The I/O interface  585  facilitates input from and output to external devices. For example the I/O interface  585  may receive input from a keyboard or mouse and may provide output to a display  587 . The I/O interface  585  is capable of facilitating input from and output to various alternative types of human interface and machine interface devices alike. 
     System  550  may also include a communication interface  590 . The communication interface  590  allows software and data to be transferred between system  550  and external devices (e.g. printers), networks, or information sources. For example, computer software or executable code may be transferred to system  550  from a network server via communication interface  590 . Examples of communication interface  590  include a modem, a network interface card (“NIC”), a wireless data card, a communications port, a PCMCIA slot and card, an infrared interface, and an IEEE 1394 fire-wire, just to name a few. 
     Communication interface  590  preferably implements industry promulgated protocol standards, such as Ethernet IEEE 802 standards, Fiber Channel, digital subscriber line (“DSL”), asynchronous digital subscriber line (“ADSL”), frame relay, asynchronous transfer mode (“ATM”), integrated digital services network (“ISDN”), personal communications services (“PCS”), transmission control protocol/Internet protocol (“TCP/IP”), serial line Internet protocol/point to point protocol (“SLIP/PPP”), and so on, but may also implement customized or non-standard interface protocols as well. 
     Software and data transferred via communication interface  590  are generally in the form of electrical communication signals  605 . These signals  605  are preferably provided to communication interface  590  via a communication channel  600 . In one embodiment, the communication channel  600  may be a wired or wireless network, or any variety of other communication links. Communication channel  600  carries signals  605  and can be implemented using a variety of wired or wireless communication means including wire or cable, fiber optics, conventional phone line, cellular phone link, wireless data communication link, radio frequency (“RF”) link, or infrared link, just to name a few. 
     Computer executable code (i.e., computer programs or software) is stored in the main memory  565  and/or the secondary memory  570 . Computer programs can also be received via communication interface  590  and stored in the main memory  565  and/or the secondary memory  570 . Such computer programs, when executed, enable the system  550  to perform the various functions of the present invention as previously described. 
     In this description, the term “computer readable medium” is used to refer to any non-transitory computer readable storage media used to provide computer executable code (e.g., software and computer programs) to the system  550 . Examples of these media include main memory  565 , secondary memory  570  (including internal memory  575 , removable medium  580 , and external storage medium  595 ), and any peripheral device communicatively coupled with communication interface  590  (including a network information server or other network device). These non-transitory computer readable mediums are means for providing executable code, programming instructions, and software to the system  550 . 
     In an embodiment that is implemented using software, the software may be stored on a computer readable medium and loaded into the system  550  by way of removable medium  580 , I/O interface  585 , or communication interface  590 . In such an embodiment, the software is loaded into the system  550  in the form of electrical communication signals  605 . The software, when executed by the processor  560 , preferably causes the processor  560  to perform the inventive features and functions previously described herein. 
     The system  550  also includes optional wireless communication components that facilitate wireless communication over a voice and over a data network (or otherwise described herein). The wireless communication components comprise an antenna system  610 , a radio system  615  and a baseband system  620 . In the system  550 , radio frequency (“RF”) signals are transmitted and received over the air by the antenna system  610  under the management of the radio system  615 . 
     In one embodiment, the antenna system  610  may comprise one or more antennae and one or more multiplexors (not shown) that perform a switching function to provide the antenna system  610  with transmit and receive signal paths. In the receive path, received RF signals can be coupled from a multiplexor to a low noise amplifier (not shown) that amplifies the received RF signal and sends the amplified signal to the radio system  615 . 
     In alternative embodiments, the radio system  615  may comprise one or more radios that are configured to communicate over various frequencies. In one embodiment, the radio system  615  may combine a demodulator (not shown) and modulator (not shown) in one integrated circuit (“IC”). The demodulator and modulator can also be separate components. In the incoming path, the demodulator strips away the RF carrier signal leaving a baseband receive audio signal, which is sent from the radio system  615  to the baseband system  620 . 
     If the received signal contains audio information, then baseband system  620  decodes the signal and converts it to an analog signal. Then the signal is amplified and sent to a speaker. The baseband system  620  also receives analog audio signals from a microphone. These analog audio signals are converted to digital signals and encoded by the baseband system  620 . The baseband system  620  also codes the digital signals for transmission and generates a baseband transmit audio signal that is routed to the modulator portion of the radio system  615 . The modulator mixes the baseband transmit audio signal with an RF carrier signal generating an RF transmit signal that is routed to the antenna system and may pass through a power amplifier (not shown). The power amplifier amplifies the RF transmit signal and routes it to the antenna system  610  where the signal is switched to the antenna port for transmission. 
     The baseband system  620  is also communicatively coupled with the processor  560 . The central processing unit  560  has access to data storage areas  565  and  570 . The central processing unit  560  is preferably configured to execute instructions (i.e., computer programs or software) that can be stored in the memory  565  or the secondary memory  570 . Computer programs can also be received from the baseband processor  610  and stored in the data storage area  565  or in secondary memory  570 , or executed upon receipt. Such computer programs, when executed, enable the system  550  to perform the various functions of the present invention as previously described. For example, data storage areas  565  may include various software modules (not shown) that are executable by processor  560 . 
     Various embodiments may also be implemented primarily in hardware using, for example, components such as application specific integrated circuits (“ASICs”), or field programmable gate arrays (“FPGAs”). Implementation of a hardware state machine capable of performing the functions described herein will also be apparent to those skilled in the relevant art. Various embodiments may also be implemented using a combination of both hardware and software. 
     Furthermore, those of skill in the art will appreciate that the various illustrative logical blocks, modules, circuits, and method steps described in connection with the above described figures and the embodiments disclosed herein can often be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled persons can implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the invention. In addition, the grouping of functions within a module, block, circuit or step is for ease of description. Specific functions or steps can be moved from one module, block or circuit to another without departing from the invention. 
     Moreover, the various illustrative logical blocks, modules, and methods described in connection with the embodiments disclosed herein can be implemented or performed with a general purpose processor, a digital signal processor (“DSP”), an ASIC, FPGA or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor can be a microprocessor, but in the alternative, the processor can be any processor, controller, microcontroller, or state machine. A processor can also be implemented as a combination of computing devices, for example, a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. 
     Additionally, the steps of a method or algorithm described in connection with the embodiments disclosed herein can be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium including a network storage medium. An exemplary storage medium can be coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium can be integral to the processor. The processor and the storage medium can also reside in an ASIC. 
     The above figures may depict exemplary configurations for the invention, which is done to aid in understanding the features and functionality that can be included in the invention. The invention is not restricted to the illustrated architectures or configurations, but can be implemented using a variety of alternative architectures and configurations. Additionally, although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features and functionality described in one or more of the individual embodiments with which they are described, but instead can be applied, alone or in some combination, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus the breadth and scope of the present invention, especially in the following claims, should not be limited by any of the above-described exemplary embodiments. 
     Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as mean “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; and adjectives such as “conventional,” “traditional,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although item, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.