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The need for high packing density has led to a requirement for photo‐imageable solder masks, and the increase in surface mount technology is rapidly expanding the use of these systems into consumer electronics in addition to the traditional high‐technology outlets. This paper compares the properties and performance of the two broad types of photo‐imageable systems—dry film solder masks and liquid systems. The manufacturing and coating requirements are outlined. Dry film solder masks are supplied by major chemical companies as high‐quality pre‐formed films while producing coatings from liquid systems is the responsibility of the printed circuit board producer. The process for producing solder masked boards from the two systems is outlined. The relative performance of the systems is compared in detail. Resolution, encapsulation, topography and reliability are considered and these are discussed as well as the requirements for fluxing and defluxing and formation of tented via holes, a highly desirable feature for SMT. Finally, the attractiveness of the more established dry film technology for surface mount boards is summarised, with a request that designers consider the features available and build these into their designs for new circuit boards. Provided the appropriate application system is used and the thickness of dry film solder mask is matched to the requirement, cost advantages can be derived from their use.

The tenting of via holes has been a controversial issue in the military arena for several years. This issue has gained importance with MIL‐STD‐2000's requirement that all circuitry and vias under components be coated to preclude entrapment of flux. This paper addresses this issue by evaluating the MIL‐Spec thermal shock reliability of solder mask as a hole fill material and as a via tent cover. The relationship of via hole to pad size on tent reliability and solder mask thickness is also investigated. This paper concludes that solder mask as a hole fill material will not pass military thermal shock requirements and that standard dry film solder mask is very sensitive to via hole and pad dimensions. The thinner and more flexible high conformance solder mask is the only material capable of passing MIL‐Spec thermal shock requirements for all via hole to pad relationships.

The development of UV curing technology has introduced new solder masks which will replace the thermally‐cured masks of the past. In doing so, processing efficiency will be increased in terms of time, energy and space saving. In considering the effective use of the new technology, thought must be given to many factors which influence the optimum performance of UV cured solder masks. The thickness of deposit will most certainly be greatly influenced by the choice of screen fabric, mesh size and squeegee which will subsequently impact upon the rate and extent of cure. One must also prepare the substrate surface adequately to compensate for the minimal wet adhesion and dwell time of a solventless ink prior to cure. Other factors such as flux chemistry, solder temperature, and soldering conditions play an important part in the performance of a solder mask and are discussed in detail. This paper was originally presented at the First Printed Circuit World Convention held at the Cafe Royal, London, in June, 1978.

This paper deals with the design of PCBs, using the dielectric properties of solder mask as an insulation layer to protect boards and components; the elimination of selective solder filling of component holes; the protection of via holes during soldering, and the preparation of artwork, with particular attention to design tolerances using dry film solder mask. Future prospects in PCB design, employing dry film solder mask, are also discussed.

Over the past few years there has been increasing utilisation of higher density surface mounting on printed wiring boards. As components and pads decrease in size, the topography of the solder mask relative to the conductors becomes an important solderability issue. There exists convincing evidence that thinner, more conformal solder mask geometries improve soldering yields of both stencilled and wave soldered surface mount components. In order to provide the solder mask coverage required for improved assembly performance, the authors critically compared several commercially available solder mask coating technologies. The coating methods were appraised according to both assembly and printed wiring board manufacturing criteria. Within this programme, seven liquid photoimageable solder masks were also evaluated. The materials were rated according to their final cured properties (electrical, mechanical, chemical performance), their manufacturability in the printed wiring board manufacturing process (maximum throughput, major defects, etc.) and their performance in assembly operations (soldering yields, propensity to ‘solder ball’ formation, white residues, scratches, etc.). The information obtained was used to choose a solder mask strategy which would not only improve assembly efficiency but also increase PWB manufacturing yields and flexibility.

Solder masks are used universally on high density printed circuit boards to reduce the occurrence of solder bridges between adjacent tracks and pads. The use of solder mask can, however, have a deleterious effect on the solderability, i.e., the solder pull‐through and top‐land wetting, of plated‐through‐hole boards. This work considers, quantitatively, the specific effect on PTH board solderability of solder mask, considering in turn the three classes of photoimageable dry film, photoimageable ink and screen printed ink. Two modes of solderability degradation have been identified: a geometrical effect that depends on the thickness of the mask and its encroachment around the solderable pads, and a contamination effect arising from the development and washing of the photoimageable masks from surfaces to be soldered subsequently.

Peel adhesion of an epoxy filleting compound and Parylene C conformal coating to plasma treated, solder mask coated substrates and the apparent contact angle of water on the treated surfaces were evaluated. No significant improvement was achieved in the case of the epoxy filleting adhesive for most solder mask coatings studied. On the other hand, Parylene C peel adhesion significantly increased after substrates were treated with air plasma and reached the level of Silane coupling agent primed substrates. This was in contrast to the decrease in Parylene adhesion to argon plasma treated substrates in comparison with the non‐treated substrates. This was related to the oxygen functionalities created on the surfaces by the air plasma versus the ablative nature of the argon plasma. No clear correlation was found between peel strength and the water contact angle in the case of the epoxy adhesive, while for the Parylene conformal coating peel strength achieved its maximum value at the middle of the contact angle range which resulted from the pretreatments applied in this study. It is concluded that air plasma is a very efficient solder mask pretreatment for Parylene conformal coating that can replace Silane primer. Also, if a calibration curve is established for each solder mask‐adhesive and solder mask‐coating system, the apparent water contact angle can serve as a convenient quality control tool for printed circuit finishing processes.

The advantages of incorporating permanent photopolymer (dry film solder mask) coatings into high density printed wiring designs to obtain maximum component density and high reliability are discussed. Although originally developed for use as solder masks, these materials offer significant advantages to the PCB designer. Specific items to be discussed include high density conductor routing, in accordance with the proposed MIL STD 275D, on the solder side and under closely spaced components, component and heat sink mounting, the use of permanent polymer coatings to avoid metallic growth problems, new industry and military specifications and standards that relate to the incorporation of photopolymer masks into PCB designs and effects of coatings on high density, controlled impedance transmission lines.

New technologies bring new challenges to those who have to convert hand‐made prototype printed circuit boards into a robust, reliable, large volume manufacturing technique. The adoption by many electronic equipment producers of surface mount technology has demanded that production managers develop and understand new skills to increase yields and obtain the maximum reliability from the product. This paper describes in some detail the methods used, many of them empirical, to obtain the best performance. Of specific interest is the importance of selecting the optimum solder mask system to increase yields and provide reliability, and the reasons for selecting a high conformance thin film solder mask are discussed. Each process is examined step‐by‐step to highlight the pitfalls, suggestions are made as to how these can be overcome and the paper concludes with the author's view of how the new technology will evolve in the future—to present further challenges to the manufacturing processes.

This paper describes how PCB designers must adjust their approach to take into account the new requirements for the production of high technology printed circuit boards using the latest plated‐through hole and surface mounting techniques. It also describes how the correct use of dry film solder masks is contributing towards the achievement of zero‐defect soldering.