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Kuang Ken. - Conveyor Belt Furnace Thermal Processing

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Book:
Conveyor Belt Furnace Thermal Processing
Author:
Kuang Ken / Xu Jinlong / Zhang Joyce
Publisher:
Springer International Publishing : Imprint : Springer
Genre:
Books / Home and family
Year:
2018
City:
Cham
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Distills more than a decades worth of application experience on furnaces into a practical book for engineers; Addresses belt furnace influences on manufacturing, assembly and packaging, efficiency, curing, and more; Focuses on lithium ion batteries, direct bond copper technologies, and solar cells. This practical book is tailored for engineers working in the industry, and condenses more than a decades worth of application experience on furnaces. The various topics discussed include conveyor furnaces, belt furnaces, solar cells, brazing furnaces, thick film furnaces, and furnace air flow and reflow. There are chapters on the influence of belt furnace and firing on silicon solar cells, thin film CIGS solar cells, dye-sensitized solar cells, crystalline solar cells, and lithium ion batteries, as well as how the processes affect the efficiency of each. The authors also address the influence of belt furnace on various processes such as metallization, engine valve heat treatment, brazing, post mold curing, and glass-to-metal sealing. The last few chapters also address Direct Bond Copper (DBC) technologies, and the effect of profile and atmosphere on the reflow process.;Chap1: Introduction -- Chap2: Understanding The Influence of Belt Furnace and Firing parameters on Efficiency of Silicon Solar Cells -- Chap3: Understanding The Influence of Belt Furnace and Firing parameters on Efficiency of Thin Film CIGS Solar Cells -- Chap4: Understanding the influence of belt furnace and sintering parameters on efficiency of dye-sensitized solar cells -- Chap5: Manufacturing Solar Cells -- Assembly & Packaging -- Chap6: A Practical Guide for Improving Crystalline Solar Cell Efficiencies through Optimization of the Firing Process -- Chap7: Study on the Effect of the Firing Process to the Energy Conversion Efficiency of Solar Cells -- Chap8: Thermal Profiling of Silicon Solar Cells During the Metallization Process -- Chap9: PID Temperature Control -- Chap10: Introduction to Materials and Firing Parameters in Thick Film Firing -- Chap11: Influence of belt furnace on engine valve heat treatment -- Chap12: The Influence of a Belt Furnace on the Brazing Process -- Chap13: The Influence of Belt Furnace on Post Mold Cure Process -- Chap14: An Introduction to Glass-to-Metal Seals -- Chap15: Furnace Temperature and Atmosphere Influences on Producing Lithium Iron Phosphate (LiFePO4) Powders for Lithium Ion Batteries -- Chap16: Direct Bond Copper (DBC) Technologies -- Chap17: Influence of Firing Temperature and Atmospheric Conditions on Processing of Directly Bonded Copper (DBC) -- Chap18: Ultrasonic belt cleaning -- Chap19: Profile and Atmosphere On Reflow Process -- Chap20: Common Maintenance and Trouble Shooting -- Chap21: Future Development.

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Springer International Publishing AG 2018

Jinlong Xu , Joyce Zhang and Ken Kuang Conveyor Belt Furnace Thermal Processing

Introduction

Andrew Kuang 1

(1)

San Diego, USA

Keywords

Thermal processing Conveyor furnace Belt furnace Furnace structure Belt furnace applications

What Is Thermal Processing?

Thermal processing is defined as the combination of temperature and time required to achieve certain desired results. In ancient times, thermal processing via wildfire was first used to cook and preserve food. Soon it was used to harden/sinter clay and then in the metal ore smelting. This high-temperature treatment has been evolving ever since, and it is widely used in both food processing and many industrial high-temperature processing today.

This book focuses on the industrial high-temperature treatment .

In todays real-life applications, high-temperature treatment (aka heat treating or heat treatment) includes a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material.

Different Types of Thermal Processing

Batch Process

For small-scale lower-volume applications, batch furnaces are used for thermal processing. Batch furnaces can be used in small-scale operations, where a high production throughput is not needed. A batch furnace typically consists of an insulated chamber, a door, and a heating component that may be powered electrically or by using gas. Different types of batch furnaces include bell, box, pit, or car bottom.

Continuous Process

Many larger-scale applications requiring a high production rate may require the use of a continuous furnace. Some of the smaller-scale processing needing specific heating and cooling profile prefer a continuous furnace too. Continuous furnaces constantly move materials through a heated chamber and comprise of a heating element, a conveyor system, and a heated compartment. Types of continuous furnaces include:

(i)
Conveyor belt furnaces (Fig. )
Fig. 1
A typical conveyor belt furnace (Photo courtesy of Hengli Eletek, Co. Ltd)

(ii)
Pusher kilns (Fig. )
Fig. 2
A typical pusher kiln (Photo courtesy of Hengli Eletek, Co. Ltd)

(iii)
Roller hearth (Fig. )
Fig. 3
A typical roller hearth furnace (Photo courtesy of Hengli Eletek, Co. Ltd)

(iv)
Others

What Is a Conveyor Belt Furnace?

A conveyor belt furnace is a device used for rapid heating of substances, using a conveyor belt to move materials through a heated chamber.

Basic Structure of Conveyor Belt Furnace

Figure shows a simplified structure of a conveyor belt furnace. The structure can be divided into a few key components :

(i)
Loading and unloading tables
(ii)
Heated chamber
(iii)
Cooling chamber
(iv)
Temperature control system

(v)

Belt driving system (Table )

Table 1

The detailed description of each section

No.	Name	Note
A	Total length	From 0.5 m like a table top bread belt toaster to over 20 m long
B	Load and unload table	The height is typically at 800 mm, for operators or robotic arms to load and unload parks after thermal processing
C	Furnace frame	This is main body for a furnace
D	Entrance vestibule zone	This section includes entrance curtain (multilayer stainless steel sheet or silicon rubber curtains). This is the important transition zone to ensure the inside furnace atmosphere is separated from outside atmosphere
E	Entrance insulation zone	Ceramic fiber insulation and transition to the heated section
F	Heated zone	The zones are heated in a controlled fashion. This section can have only one zone or multiple zones
G	Exit insulation zone	Ceramic fiber insulation and transition to the cooling section in a controlled way
H	Free cooling zone	Gas inlet and test welding reserve place
I	Water cooling zone	Some furnaces have this feature of allow increased cooling rate
J	Exit vestibule zone	This section includes entrance curtain (multilayer stainless steel sheet or silicon rubber curtains). This is the important transition zone to ensure the inside furnace atmosphere is separated from outside atmosphere
K	Furnace height	Exclude the mounting feet and exhaust stack height
L	Equipment operation panel	Typically the main control panel/machine and human interface are located here

Fig. 4

A typical conveyor belt furnace layout (Courtesy of Hengli Eletek, Co. Ltd.)

As discussed above, very often a belt furnaces inside atmosphere is separated from outside atmosphere. This way is to ensure that the parts are processed in desired atmosphere (air, H2/N2, N2, Ar, and controlled moisture content/dew point).

Below shows a simplified atmosphere control system design .

In this simplified design, there are eight atmosphere pipes. A, B, C, and D: the measuring range of five nitrogen flowmeters is 12120 l/min, and one nitrogen Venturi exhaust flowmeter has 550 L/min range. Please see Fig. for detailed gas layout.

Fig. 5

Simplified gas layout drawing (Courtesy of Hengli Eletek, Co. Ltd)

Table 2

Simplified furnace atmosphere control system

Code	Name	Explanation
A	Entrance curtains	Import nitrogen curtain, prevent outside air from entering the chamber
B	Entrance gas inlet	Nitrogen purge products. Prevent outside air from entering the chamber

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