This section provides overview, applications, and principles of flux spraying machines. Also, please take a look at the list of 7 spray fluxer manufacturers and their company rankings.
A spray fluxer is a device used to apply flux, a soldering accelerator, when automated soldering equipment performs soldering.
Soldering is an important operation that determines quality in the manufacturing of electronic components and circuit boards. In recent years, automated soldering equipment has been introduced to reduce human costs and improve efficiency.
By using a spray fluxer, foreign matter and oxide film are removed from the area to be soldered, and surface tension is lowered to ensure thin and uniform soldering.
Spray fluxers are used in combination with automated soldering equipment.
In general, solder contains flux, which evaporates at temperatures close to the melting point of the solder. Since the solder bath of automated soldering equipment is always kept at a high temperature, solder with flux cannot be used.
Therefore, flux-free solder is used and flux is applied separately by spray fluxers. In this way, it is used to improve the soldering quality of automated soldering equipment.
When solder is heated and melted, it tries to form a spherical shape due to its own surface tension. In this state, the solder cannot be soldered properly.
Therefore, the key to high-quality soldering is to be able to apply solder flatly. In this case, the use of flux removes foreign matter and oxide film from the board surface, thereby lowering surface tension and allowing the melted solder to spread thinly. Flux is a liquid solution consisting mainly of pine resin (rosin), to which zinc chloride and ammonium chloride are added.
Pine resin contains a large amount of organic acids such as abietic acid, which activates at around 170°C, close to the melting point of solder, and removes copper oxides.
There are two types of spray fluxers used to apply flux: foaming type and spray type.
Flux is applied by dipping the substrate into the foamed flux using a foaming element. While this method can apply a sufficient amount of flux, it has the disadvantages of using a large amount of flux and being costly because the solvent volatilizes during the foaming process.
Spray flux can be applied thinly and evenly by atomizing the flux. Compared to the foaming method, the spray fluxers uses only the necessary amount of flux when needed, making it cost-effective and easy to use, and it is used by many flexers.
The application amount of spray fluxers are designed based on the know-how cultivated in the field by each manufacturer.
The component surface of a control board on which electronic components are mounted is called the reflow surface, and the metal mask and cream solder make it relatively easy to control its solder amount. On the other hand, the solder flow surface, which is the backside of the mounted components, is in a different situation.
For the solder flow surface, pre-flux is always applied before the flow soldering process in order to improve solder adhesion when passing through the solder bath, which is a bath with a jet of solder. The amount of pre-flux applied has a significant impact on the quality of the flow solder on the board.
Spray fluxers processing time takes about 30 seconds.
In addition to the spray method, the spray fluxers process also includes a firing method in which compressed air is injected into the flux tank's firing tube to create flux bubbles, which are then applied to the backside of the board. However, most manufacturers use the spray method because it allows better control of the amount of flux applied and offers better quality.
Even in such a situation, the conditions necessary to improve the quality of flux application are the elimination of unevenness, linearity of application amount (easy to control), and stability of repeatability. In order to satisfy these conditions, the current situation is that, day and night, the production site divides the substrates to be subjected to each spray fluxers into zones, and then sets the conditions for each actual product so that all the conditions can be satisfied. This condition creation is a burdensome task and has become a challenge for technological innovation in this field.
One type of spray fluxers, the spray type spray fluxers, has a unique structure that utilizes a nozzle and spray.
Spray fluxers are a device that applies a solder promoter called flux to improve solder quality.
In the typical spray type spray fluxers structure, a nozzle sucks up flux from a can and sprays the atomized flux directly. The nozzle that sucks the flux then operates laterally across the substrate, synchronizing with the operation of the conveyor to apply flux to all flow surfaces.
This method is characterized by its high cost, complicated management (tool cleaning is required), uniform application to the entire substrate surface, and controllable film thickness on the substrate surface. Therefore, in terms of quality, the spray type spray fluxers are the best.
*Including some distributors, etc.
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