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thick circuits, as well as those requiring improved thermal properties, the 170 C to 180 C Tg FR-4s have become the material of choice With the advent of lead-free assembly, Td and other properties must also be considered along with Tg Further, as noted above, higher Tg does not always translate to better performance in lead-free assembly applications In other words, as the range of end-use applications has grown, so has the range of available FR-4 materials In addition, the components used in FR-4 materials, particularly woven fiberglass cloth and epoxy resins, provide a very good combination of performance, processability, and cost The range of woven fiberglass cloth styles available makes it easy to control dielectric and overall circuit thicknesses As noted earlier, the range of epoxy resin types also makes it relatively simple to tailor material properties to end-use applications.

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The combination of good electrical, thermal, and mechanical properties of epoxies also explains why they have become the primary type of resin used in printed circuits Epoxy-based materials are also relatively easy to process through conventional printed circuit manufacturing processes, at least in comparison to some of the other types of materials available The processability of these materials has helped control the cost of FR-4-based printed circuits Last, the development of FR-4 materials took advantage of established manufacturing processes and materials Weaving processes have been in place for many years The fundamental process of weaving fiberglass yarns into glass cloth is not so different from weaving textile yarns into cloth fabrics Using the same basic manufacturing technology avoided additional upfront research and development costs, but more importantly it avoids to some extent highly specialized capital assets and aids in achieving economies of scope for the suppliers of fiberglass cloth.

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The result is good control of the costs of these materials Likewise, epoxy resins have been in use in a wide range of applications outside of printed circuits, resulting in a very large installed manufacturing base for these types of materials This also results in good cost competitiveness for epoxy resins In summary, the range of FR-4 types and their unique combination of performance, processability and cost characteristics have made them the workhorse of the printed circuit industry..

Good Thermometry Techniques Understanding the thermal impact of the oven on the board and the board on the oven is critical for a controlled and reproducible reflow process. Thermometry is the only practical method for validating these influences by means of oven profiling. Oven-and-board interactions are explored in this presoldering step and the oven is adjusted for proper time-temperature profile of the PWB with the parts to be soldered. Some of the most important process points determined through board and oven profiling are:

Heating-cooling ramps and ensuring that they are within the recommended bounds prescribed in the surface-mount device (SMD) component and solder paste specifications Peak process temperature and duration Dependency on the heater types, quantities, cooling methods on board, and component materials Conveyor speed Heat distribution along the oven s width Heating characteristics of the PWB and the SMD components upon it Rate at which the oven reacts to the board s presence

Product Profile Board All of the preceding and many more variables have dramatic impact on the soldering process The only way to assess these is to gauge accurately the thermal energy distribution in the oven in the presence and absence of the board Most process engineers trust their favorite profiling board to determine the health of their reflow oven or assess the performance of a new oven prior to purchase The profiling board is simply a thermocouple-instrumented product board or test vehicle that is run through the oven for the purpose of determining the oven s effect on the board for given heater and conveyor speed set points The thermocouples trace the temperature profile of the oven as seen by the component lead or package as the board is conveyed through the oven for reflow.

However, reliance on a product board to determine oven performance may mask some inherent problems with the reflow oven If the board is not thermally balanced in terms of components or board innerlayers, it may not be able to detect a strong transverse (rail-to-rail) thermal differential It is for this reason that a balanced oven diagnostic profiling device should be made and run to assess oven performance independent of a product board That is not to say that the oven diagnostic board is a direct replacement for the product profiling boardThe latter is to verify that the critical sectors of the board or, better yet, device leads are heating per set profile Thermocouples for this board are deployed at the leading edge, trailing edge, center, and sides, with the thermocouple beads ideally embedded within the solder joints of disparate component types.

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