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0 mil range, with some designs requiring dams as narrow as 10 to 15 mils wide Producing features this fine is not possible with all solder mask materials, and the imaging process for very fine features will typically be modified from normal production with wider dams..

Assembly Considerations 33.4.5.1 Thickness. When PCBs had all through hole components, solder mask thickness was not of much concern. However, with the advent of surface-mount technology in the 1980s, excessive solder mask thickness caused assembly problems, including:

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Tombstoning of discrete devices in reflow soldering Excessive opens with discrete devices in wave soldering Solder paste printing problems (excessive paste, solder balls, paste on back of stencil, etc.)

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Flip-chip assembly, with its finer pitch, has placed further restrictions on the maximum mask thickness. These thickness restrictions effectively eliminated dry film solder mask in most applications and relegated it to a specialty product for special applications. 33.4.5.2 Cleanliness. After PCBs have been assembled, they must meet specific ionic and visible cleanliness requirements. It is important that PCBs produced with the specific solder mask through the normal process be qualified through the assembly process to ascertain whether the production parts will meet expectations. Each solder mask and flux combination throughout the assembly process may give a different cleanliness result. 33.4.5.3 Solder Balls. Some assembly processes are more prone to generate solder balls than others. Prequalification of the solder mask with the assembly chemistries and processes is essential to predict production performance. If solder balls occur during assembly, in some cases they can be reduced by using a mask with a different surface finish. Satin or matte products sometimes have less of a tendency to have solder balls. Modifying the solder mask cure can have an effect on the level of solder balls also consult with the solder mask supplier before deviating from its recommended cure process. 33.4.5.4 Assembly Material and Process Compatibility. When qualifying a new solder mask or new PCB supplier, it is critical that all existing materials and processes be evaluated for compatibility before production is scaled up. This should help avoid major issues where there is a large quantity of PCBs awaiting assembly that cannot be assembled with the existing assembly materials and processes. Care should be taken to include evaluation of:

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Soldering fluxes and pastes Cleaning agents Multiple heat exposures Adhesives Underfills Temporary solder masks Tapes Anything else in assembly that depends upon the surface of the solder mask

33.4.5.5 Conformal Coating Compatibility. Again, qualification of the solder mask, through all of the fabrication processes, is required to ensure that no problems with production boards arise. Since conformal coating is applied after assembly, a significant amount of processing and exposure to other chemistries will have happened since the solder mask has been applied. The conformal coating compatibility testing should be done on a board that has been through all of the assembly processing. The cleanliness of the PCB surface after the final assembly process has a great impact upon the adhesion of the conformal coating. One cannot

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expect conformal coating to adhere well to a dirty board. These coatings were not meant to be applied over a no-clean flux, but over a clean substrate.

Application Method for Installed Equipment Choose solder mask that is compatible with the existing or proposed application method. Not all solder masks can be screen printed, sprayed, and curtain-coated. Consult with the solder mask supplier for the appropriate solder mask for your application method.

Gloss Solder masks are available in different levels of gloss. Typical terminology for finishes includes gloss, semigloss, satin or semimatte, and matte. These finishes represent a certain level of reflectivity of light and microroughness. Gloss level is generally specified by end users for assembly or cosmetic reasons.

Color Likewise, different levels of color may be available. Most solder mask is green, but many other colors, such as red, blue, black, yellow, and white, are often specified. Some solder masks are specified to be clear.

Packaging versus PCB When solder mask is used on substrates that will become part of a semiconductor package. The JEDEC Solid State Technology Association (once known as the Joint Electron Device Engineering Council) specifications apply in addition to the IPC specifications. JEDEC specifications include additional, more aggressive testing that generally requires a more robust solder mask. Low moisture absorption is important for a mask used in packaging applications.

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