Publication date: 10 December 2009
A. The market need for lead-free solder reflow presents its own unique challenges due to the requirement of process temperatures that are critically close to the destruct temperature of the components that are being attached. The Pyramax system’s unique closed-loop convection control is designed to provide a repeatable tight temperature window that is optimized for lead-free solder reflow.
In addition, the new SAC lead-free solders succeeded in demonstrating that some low-end process equipment was not up to the task. In the case of reflow ovens, the major issues are higher temperature capability, uniformity, repeatability and handling of the flux. Most SAC alloy issues have been resolved over the last few years, but some of the reliability studies show that the sheer strength of SAC is slightly lower than eutectic lead solder. It is common knowledge in the material sciences that materials with large grains usually have decreased strength. It is also known that fast cooling produces smaller grains. Thus, a number of people are asking for fast cooling rates to minimize the grain size of SAC.
On the other hand, manufacturers that reflow large BGAs are advocating slower cooling rates. It is believed that increased ball shearing has surfaced with SAC because of the lower strength of lead-free solder. The difference in thermal contraction between the board and BGA develops stress during cooling. By limiting the cooling rate, the thermally imposed stress can be minimized. Whether you need fast or slow cooling, there are a number of alternatives available on our systems to help the reflow process engineer optimize the thermal profile for every kind of board.
A. Today, most companies are focusing heavily on costs. Electronics manufacturers need to control their operational costs in order to make their products more competitive. However, the decision to purchase capital equipment is about more than just the price. Therefore, when they are making purchasing decisions, companies are looking for equipment that offers the lowest cost of ownership, whilst at the same time offers best performance. As a reflow oven provider for more than 20 years, BTU has endeavoured to focus on developing new technologies to further lower cost of ownership and improve thermal performance for its customers. BTU’s goal is to provide customers with the advanced systems they need to keep their competitive edge. To that end, the company provides extremely competitive and flexible pricing.
A. As one of the major transitions of the recession, electronics manufacturers are more focused on lean operations. Productivity, low maintenance, low running costs and stability will be the main criteria to evaluate their equipment. BTU’s systems provide solutions to all of these aspects.
Productivity can be guaranteed by choosing the right length of equipment and therefore the zones needed, depending on the throughput requirements for each line. BTU Pyramax reflow systems offer very low maintenance thanks to a very robust design, which ensures the highest uptime for the system. They also provide an efficient proprietary flux management system, which minimizes residues in the process chamber. Running costs are kept to a minimum with a low Nitrogen package, soft start features that reduce power during start up and a closed-loop water chiller, or efficient air coolers, to help to reduce water consumption, keeping it at very low levels.
BTU Pyramax systems have a reputation, globally for their reliability and robustness. Even after years in the production process the residual value in terms of resell is relatively high. Stability of the process is obtained by an extremely efficient thermal transfer and a totally closed-loop controlled process. This includes control of the convection procedure, temperatures and conveyor speed.
A. We introduced two new Pyramax models in 2008; the six-zone Pyramax75 and the twelve-zone Pyramax150z12. These new offerings were developed jointly by BTU engineers in China and the U.S.
The Pyramax75 is our entry level reflow system. It corresponds best to customers looking for a system with high thermal capabilities, limited footprint, low cost of ownership and one which can work in-line or as a stand-alone unit and at a very competitive price.
If very high throughput and high performance are needed then we recommend our new Pyramax150z12. The system can work under Air or Nitrogen atmosphere at low ppm levels and reduced Nitrogen consumption, or even with Air Doping when higher Oxygen levels are needed. Low N2 package has been optimized to guarantee low consumption. With these two new models, we now offer a complete range of reflow systems with 6, 8, 10 and 12 heated zones, and with heated lengths from 1.9 to 3.8 meter. All models are built on the same modular platform with common components.
We work very hard to ensure that each purchase is designed to suit each individual customer. So, all Pyramax systems are available in different configurations based on their individual needs. A wide variety of transport system configurations offer solutions for all types of production. Our 3rd generation of patented flux management systems increase uptime thanks to the possibility it offers to clean the system during production. Our flux management system is structured to isolate the flux residues outside the main process chamber, thereby helping to maintain the integrity of the atmosphere and facilitate easy disposal. Other new features include our Bar Code reader solutions with automatic recipe change and data collecting capabilities, as well as new multilingual software.
We have just launched our Precision Center Support, which provides simplified mechanics for increased uptime and reliability, whilst at the same time decreased cost. It is an interesting alternative to our Hide-Away Center Support. The new center support option provides one programmable center support for eliminating the sagging or warping of wide or thin printed circuit boards. This system allows recipe programming of the width (placement). This is accomplished using a tabbed chain riding in an aluminium extrusion through the oven process chamber. The center support can be located anywhere between the rail edge conveyor pins, or when not required it can be moved out of the way, close to the fixed rail edge conveyor pin to a “parked” position. This allows full use of the rail edge conveyor width without any obstructions or effects on minimum product width. This solution offers maximum flexibility.
BTU’s global presence is key to the company’s success. The industries we serve are international in nature with markets and manufacturing operations reaching the far corners of the world. With strategic foresight, BTU established its own global presence many years ago – a bold move that is now a cornerstone for our future growth.
BTU designs and manufactures its products in Billerica, Massachusetts and Shanghai, China. World-class sales and customer support are provided in over 30 countries. Half of BTU’s employees are located outside the U.S., and a large portion of the company’s systems are manufactured in China. The results include strong customer relations, real-time market intelligence, low cost manufacturing, reduced shipping expense, quick deliveries and global sourcing of parts. BTU matches the international nature of its customers and markets by being an international company that’s in the right place at the right time.
A.BTU offers solar processing equipment for both silicon and thin film photovoltaics. In thin film, our equipment is used for both the CIGS and CdTe processes. We leverage our experience with large-scale, custom, in-line thermal processing systems. These systems can be well over 40 meters in length and include specialized features such as coating capability and novel atmospheres. The system design is scalable and systems are sold for lab, pilot and production sized applications.
Silicon PV applications are served by our metallization process systems and in-line diffusion processes and systems. BTU’s solar cell processing equipment includes not only in-line thermal systems but coating and printing technology as well. For the metallization process, BTU offers a complete line of Rapid Thermal Processing furnaces, utilizing near infrared heating technology which is used for contact drying and firing. Systems come in varying lengths and widths to suit specific throughput requirements. Metallization printing equipment is also available through BTU’s strategic partnership with a third party supplier.
A.We are extremely proud to receive the ‘Industry Choice’ International Solar Technology Award, presented during a ceremony at the Intersolar show in Munich for our MERIDIAN™ In-line Diffusion System. The award recognizes achievements in the creation and development of solar technology, with an emphasis on real-world technical advancements required throughout the supply chain, to push solar power toward grid-parity without government subsidies.
The MERIDIAN™ In-line Diffusion System reduces total cost of ownership over batch processing and offers process control features that can lead to improved cell efficiency. We have received very positive feedback from our customers who are using this system.
The system features the MERIDIAN™ phosphorus coater, which includes key advances such as back-side and top-side coating and integrated wafer drying. The system can be configured to achieve up to 1500 156-mm wafers per hour. The in-line process offers reduced wafer handling and greater throughput than traditional batch processing. Reduced handling translates into lower breakage rates, improved yield and that all important lower cost of ownership.
Close working relationships with Universities and well known R&D centres, as well as between our key customers and our product engineering teams enable us to incorporate our customers’ feedback and needs into our product development efforts. These relationships with key partners facilitate product development for next generation processes and technologies for our Electronics products range and in the rapidly growing energy generation market.
In 2009 we have already exhibited at major European SMT and PV shows and we will continue till the end of the year at various locations showing our latest Pyramax systems as well as our new Tritan PV firing furnace. With local partners we will also run seminars to present new processes and latest equipment developments.
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