FIELD OF THE INVENTION

This disclosure relates to manufacturing apparatus for attachment to wave solder machines for facilitating the soldering of terminals on the underside of a printed circuit board without touching or wetting the gold contact area of the printed circuit board.

BACKGROUND OF THE INVENTION

In all digital module manufacturing industries today, hundreds of thousands of printed circuit boards must be assembled with proper components mounted therein with subsequent passage through a soldering process whereby one side of the printed circuit board is subject to a soldering operation whereby hundreds of terminal points are soldered for reliable electrical connectivity.

In this manufacturing process, general usage is made of wave soldering machines whereby a conveyer having conveyor fingers will carry sequences of printed circuit boards in forward motion along a pair of guard rails

whereby the underside of the printed circuit board is passed over a molten bath of solder which is agitated to rise in waves against the underside of the printed circuit board. In this particular operation which is repeated thousands of times in digital unit. manuf cturing operations, it has been the standard practice to "protect" one side of the printed circuit board from being wetted or contacted by the hot molten solder. This particular protected portion of the printed circuit board is the portion comprising a series of gold contacts which connect the components mounted on the printed circuit board to the mother board or other types of connectors for operation in a digital unit. The general practice has been to manually apply

Kapton tape to the gold contact area of each of the thousands of printed circuit boards so that when the printed circuit board passes over the wave solder pot, it is ^' essentially insulated fro ^• contact by the hot molten solder.

There, are many disadvantages to this method of protecting the gold contact areas. Since the Kapton tape is not only an unusually expensive item which is used in large quantities, but additionally, considerable and precise labor time is involved in both applying the Kapton tape initially and subsequently removing the tape from the gold plated contacts. Unfortunately, various levels of contamination of the gold contact area can occur due to the application of the adhesive Kapton tape with undesired results.

It has long been an annoying problem to attempt to find a better method of accomplishing the wave solder operation without contamination or degradation of the gold contacts.

Various attempts have been made to provide othe forms of shielding devices to prevent the molten solder from wetting the gold contact area, but to this date, no outstandingly successful and efficient methods have been developed.

The presently disclosed- system for efficient prevention of any solder-wetting or contact to the gold connection areas on the printed circuit board describes an apparatus which can be fitted onto a wave solder machine and which will provide a finger shield in proximity to the printed circuit board such that the hot molten solder is prevented from approaching the area of the printed circuit board which carries the gold connecting contact areas.

SUMMARY OF THE INVENTION

The newly developed auxiliary apparatus described herein provides an adjustable framework for attachment to a wave solder machine such that the conveying fingers of the wave soldering machine will be guided by the auxiliary apparatus so as to carry and convey each printed circuit board slowly across a molten solder pot (such as a T-wave solder pot) so as to accomplish the action of properly soldering all of the underside terminal contacts, yet at the same time without contacting or wetting any of the gold plated contacts along one side of the printed circuit board.

This is accomplished by the use of a frame apparatus having a front rail and a back rail to support a pair of perpendicular guide bars on which the inner sides provide a finger shield which dips into the molten solder and causes the formation of a meniscus pattern which prevents the molten solder from extending over into the gold contact area.

The finger shield is constructed of the metal titanium which has a very low molecular attraction to molten solder (tin-lead) . This causes a negative (non-wetting) meniscus at the finger shield edge contact to the hot molten solder while at the same time a positive (wetting) meniscus exists between the molten solder and the underside of the printed circuit board.

With these conditions, the molten solder is caused to "wet" that portion of the underside of the printed circuit board which requires the solder terminal connections without any leakage onto that portion of the printed circuit board which carries the gold plated contact connections.

In this wise, the need to "mask" the gold contacts with expensive covering tape is eliminated in addition to reducing the costs in labor to apply and to remove the tape. Further, the cost of suitable insulating tape, suqh as Kapton, and any resulting contamination from glue residue is further eliminated. The bracket apparatus which supports the guide bars holding the finger shields is capable of adjustment as between the left finger shield and right finger shield so that different size printed circuit boards can be accomodated. Two adjustment wheels, a front adjustment wheel and a back adjustment wheel, are provided in order to provide for a precision adjustment of the left finger shield and the right finger shield so that it does not matter on which side of the printed circuit board there happens to be gold plated connection contacts, since either the left side or the right side or both can be accomodated so as to prevent any wetting or soldering operation while performing the underside solder bath operation.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is an overall plan view of the auxiliar additive bracket apparatus which can be attached to a wav solder machine so as to provide guidance of printed circui boards across the molten solder pot and whereby in eac case the positions of the left finger shield and the righ finger shield can be precisely located.

Figure 2 is a schematic drawing showing a printe circuit board placed in proximity to a finger shield an molten solder such that a positive meniscus and a negativ meniscus is formed.

Figure 3 is a schematic drawing showing a printe circuit board being carried by a conveyor finger and th proximate use of the titanium finger shield to provid insulation to the gold contact area of the printed circui board.

Figure 4 is a drawing of the right hand guide ba (14g of FIG. 1A) showing the inside edge 15 of the finge shield. Figure 5 is a drawing of the guide bar (14g, 15g) as it sits vertically over the solder pot (of FIG. 1A) .

BRIEF DESCRIPTION OF PREFERRED EMBODIMENT

Referring to Figure 1, there is seen the auxiliar portable attachment apparatus 80 for attachment onto a wave solder machine whereby the conveyer fingers 40 (Figure 3) are engaged to carry a printed circuit board 30 across a molten wave solder bath 42 of Figure IB.

As seen in Figure 1A, there is provided a frame mechanism consisting of mounting rails with a front rail I f and a back rail 7j-,. The front rail 7f has a front left bracket 6 and a front right bracket 5 which attaches to and supports the guide bars 15g and 14g. Likewise at the back

side there is a back left bracket 2 and a back right bracket 1 which support the other ends of the guide bars 15g and 14 _g .

In Figure IB the guide bars 14 _g and 15 _g will be seen to form the guidance mechanism through which the printed circuit board 30 is conveyed toward the molten solder bath 42. And as seen in Figure 3 the conveyor fingers 40 are used to hold and carry the printed circuit board along the guide bars 15 _g and 14 _g in order to expose the underside of the printed circuit board onto the molten solder bath 42.

The distance between the guide bars 14 _g and 15 _g is adjustable in order to accomodate different sizes of printed circuit boards. These adjustments are accomplished by use of a front adjustment wheel 24 and a back adjustment wheel 25 shown in Figure 1A. The height and azimuth adjustment, which regulates proximity of the finger shield edge - (15e, FIG. 2) to the underside of board 30, is arranged by set screws 20 _a , 20^, 20 _c , 20^ of FIG. 1A. The guide bar 15 _g is provided .with a left finger shield 15 which is shown in greater detail in Figure 3. Similarly guide bar 14 _g provides a right finger shield 14 as seen in Figure 1A.

The front adjustment wheel 24 activates a lead screw 16 working through guide blocks 10 and 11 in order to adjust the position of the guide bar 15 _g and the left finger shield 15. Similarly the back adjustment wheel 25 activates the lead screw 17 through the guide blocks 12 and 13 in order to adjust the position of guide bar 14 _g and the right finger shield 14. These adjustment wheels permit operator adjustment without need to approach the hot metal parts and eliminate the risk of injury due to burns.

Thus while the frame assembly 80 ^: is resting upon the wave solder pot, a very precise adjustment is possible as to the position of the left -inger shield 15 and of the right finger shield 14 in order to accomodate any size printed circuit board which is conveyed through the molten wave solder machinery.

A left stabilizer bar 3 and a right stabilizer bar

3' having mounting blocks 4 and 4 ^* are used to provide greater rigidity to the frame structure. Additional details are shown of the back block track 9 and the front block track 8 indicating the cap screw 22 and the dowel 19.

Referring to Figure 3 there is shown a schematic drawing indicating how the printed circuit board 30 is held and conveyed by a conveyor finger 40. This drawing shows only one side of the printed circuit board with a conveyor finger 40 in that the opposite side of the printed circuit board is held by a similar conveyor finger 40 in order to support the. printed circuit board at both ends.

Figure 3 indicates further the details of the left finger shield 15 and the guide bar 15 _g . A similar situation would occur on the opposite side of the printed circuit board with regard to the right finger shield 14 and the right guide bar 14 _g . Only one side of the printed circuit board is shown in Figure 3. As seen in Figure 3 the adjustable guide bar 15 _g provides an optimum angular extension of approximately 30° to form the finger shield 15. The effect of the finger shield 15 is to prevent any of the hot molten solder from the wave solder pot 42 from wetting or penetrating to the area of the printed circuit board which holds the gold plated contacts. Thus the solder wetting and contact is limited only to that part of the printed circuit board

where terminal points are desired to be soldered for electrical connectivity.

As seen in Figure 2, the finger shield 15 is shown in greater detail. Since the finger shield 15 is made of titanium metal, which has the characteristic of "non-wettability" to molten solder, there is formed a negative (non-wetting) meniscus between the finger shield and the molten solder while the contact area between the terminals of the printed circuit board and the molten solder forms a positive (wetting) meniscus. The symbol PHI ( Φ ) is used to define the angle made in the interface between the liquid solder and the finger shield ( Φ_ ) in one case and the angle between the liquid solder and the underside of the printed circuit board (Φ2)« Since the titanium has a low molecular attraction to the molten solder which is composed of a tin-lead alloy, then the negative meniscus which is formed can be defined by using the symbol PHI (Φ ) as a measure of the wetting angle. In the case of the negative meniscus, the wetting angle or PHI { _ ) is less than 90°. On the other hand, the wetting angle as between the underside soldering terminals of the printed circuit board and the molten solder is greater than 90°, that is to say PHI (Φ 2) i- ^s greater than 90° thus forming a positive meniscus. The titanium material plus the wetting angle plus the location, shape and position of the finger shield cause the solder to be accurately controlled along a desired boundary, thus eliminating the need to "mask" the gold plated contacts with a tape covering. This provides a considerable reduction in the cost of applying and removing the tape, reduces the cost by eliminating the use of tape and also eliminates contamination which would normally occur from the glue residue on the covering tape.

So e older methods were often tried with a finger shield which was directly perpendicular to the printed circuit board at a position of approximately one-thousandth of an inch from the printed circuit board. The severe disadvantage of this situation was that capillary action occurred between the shield and the printed circuit which pulled solder through the opening and onto the gold contact areas. This caused solder on the gold contacts which had to be removed and replated, leading to excessive and costly rework. As a result of these problems the use of Kapton tape began to be used to cover the gold contact area with all the difficulties and problems that that procedure led to, as described previously.

The particular design of the guide bar and finger shield 15 is of critical importance to the operation of the auxiliary apparatus. As can be seen in FIGs. 2 and 3, the gap between the edge 15e of the finger 15 and the printed circuit board 30 must be on the order of fifty thousandths of an inch plus or minus twenty thousandths, that is to say 0.050 plus or minus 0.020. The finger shield 15 is raised at a 30° angle to the horizontal.

In FIG. 4, the right guide bar 14 _g is shown with the right finger shield 14 having the finger edge 15 _e .

A cutout hole called the "weep hole" 15 _w is used as a safety drain to release any liquid solder which may have accidently gotten into the inner area of the guide bar 15 _g of FIG. 3.

In FIG. 5, there is seen the length of the finger shield edge 15 _e (FIG. 2) with the tapered endings 15 _t which help to prevent any hard collisions between the moving board 30 and the finger shield 15.

There has been disclosed herein an auxiliary attachment apparatus for a wave solder machine whereby

printed circuit boards of various sizes and configurations can be accomodated for conveyance across the molten solder bath of a wave solder machine. Of particular significance for the auxiliary attachment is the provision of two finger shields which can be adjustably placed at each end of the printed circuit board so as to prevent any solder wetting of the gold contacts which are to be isolated from the solder bath. The sides of the auxiliary apparatus provide two guide bars 14 _g and 15 _g which have on the inner side thereof finger shields respectively designated as 14 and 15 on each side whereby the finger shield is made of titanium and has a tapered edge coming within 0.050 of an inch of the printed circuit board so as to act in - causing a "negative meniscus" between the titanium edge and the solder bath, thus preventing any seepage of molten solder into the gold contact area. Of considerable importance is •the criticality of the angle of the finger, the edge of the finger and the proximity of the finger to the printed circuit board which is very carefully controlled. " While the above auxiliary attachment apparatus for a wave solder machine has been described in one particular embodiment, other variations thereof may be provided which effectively result in the same advantages, thus the preceeding disclosure should be considered in the light of the attached claims which follow herein.