Abstract:
The invention relates to a lead-free solder paste comprising a solder paste flux and solder alloy particles that are substantially lead-free wherein the solder paste flux comprises resin dissolved in a solvent and also includes undissolved resin particles less than 25 μm in size homogenously dispersed therein to provide improved solder alloy powder coalescence and substrate surface wetting while maintaining appropriate solder paste rheology for use in printed circuit board assembly processes.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to lead-free solder paste for use in lead-free soldering of components in the electronics industry. 
     2. Brief Description of Related Technology 
     Solder paste is a homogenous, stable suspension of solder particles in a solder paste flux and has many applications in the electronics industry, particularly in the manufacture of printed circuit boards (PCB). 
     Reflow soldering is used in the automated manufacture of PCB, wherein electronic components are surface mounted on PCB to which a solder paste has previously been applied by a method such as screen printing, stencilling or dispensing. The PCB is then subjected to a sufficiently high temperature, to cause the solder paste flux and the solder particles to liquefy and to join the components in place on the PCB. The heat can be supplied by, for example, infrared, heated conveyor belt or convective means. 
     Soldering will not take place without solder paste flux, which is required to improve the coalescence of the molten solder particles and the wetting of metallic substrates. In particular, solder paste flux removes oxide layers from the solder and joint surfaces, transports reaction products away from the soldering zone, and protects the clean joint surfaces from oxidation until soldering has taken place. Solder paste flux also acts as a heat transfer medium which ensures that all parts of the joint reach a temperature above the melting point of the solder particles. 
     Many solder paste fluxes are based on rosin, which is a natural material obtained from the sap of pine trees and contains isomers of abietic acid. Synthetic resins may also be used. These materials may be referred to generically as resins and as used herein the term “resin” includes natural resins such as rosin, chemically modified rosin, and synthetic resins. To form solder paste fluxes the resins are dispersed in solvents, together with additional activators and gelling agents. 
     Activators are added to decompose and remove any oxide film existing in the portion where soldering is going to be carried out, and are usually organic compounds containing halides, typically amine hydrohalogenides, such as diethylamine hydrochloride or weak halide-free organic acids. The resin may be a weak acidic activator but it is also added to protect the metals from oxidation during solder paste reflow. The organic solvent dissolves and supplies the resin and activators to the portion to be soldered and is typically an alcohol, glycol, glycol ether, or ester. Most of the organic solvent is evaporated during the preheating step of soldering. A gelling agent such as ethyl cellulose or modified castor oil is used to maintain the necessary viscosity of the solder paste flux. This provides the correct physical characteristics to maintain a homogenous dispersion of solder powder particles, to provide a material that can be screen printed and to hold electronic components in place before the soldering process is carried out. It has hitherto been regarded as essential in the formulation of resin based solder paste fluxes that the resin is completely dissolved in the solvent. 
     Use of high boiling range solvents is desirable in the formulation of solder paste fluxes because it provides for a more robust solder paste printing process and shows improved ability to hold electronic components in place before the reflow assembly process. However, it has now been found by thermogravimetric analysis of solder paste through a typical PCB reflow process that solvent loss continues throughout reflow and that a significant amount of solvent is present in the molten resin before and even during the melting of solder alloy particles. It has been postulated that these solvents plasticise the resins so that they are more fluid during the reflow process and this has the disadvantage that it allows the flux to move away from the region where the cleaning behaviour is necessary and reduces the ability of the solder paste flux to prevent re-oxidation of the metal surfaces. As the reflow process becomes more aggressive, i.e., longer duration and/or higher temperatures, the effects of re-oxidation become more apparent. 
     Adding extra activators to the solder paste flux can improve the ability of the flux to withstand aggressive reflow processes such as in lead-free soldering, but significant additional amounts of metal salts will be produced and left in flux residues after reflow. If the same flux is used under less aggressive conditions there will be significant additional quantities of unused activator in the residues. Both the metal salts and the unused activator reduce the electrical integrity of the flux residues. Using additional activators and/or developing improved halide-containing activators is thus not very effective in improving the resistance of solder pastes in aggressive reflow processes. Additional activators also adversely affect the shelf life of solder pastes and reduce the resistance of the solder paste to drying during the printing process. 
     U.S. Pat. No. 4,419,146 is directed to the manufacture of useable fluxes from solvent/activator combinations that are not soluble in one another. Specifically, solder flux compositions are disclosed which are prepared by forming a dispersion of a flux material in a liquid in which the flux is substantially insoluble, wherein the flux material is a mixture of tartaric acid and sarcosine and the liquid is isopropyl alcohol with or without water. JP 63-123,592 is directed to a cream solder comprising a tin or lead solder alloy with a flux with a first gel flux comprising a rosin hardly soluble in organic solvent and an activator and a second gel flux comprising a rosin easily soluble in the organic solvent. 
     In the past most solder compositions used were of the tin-lead type which proved useful in most common applications. However, the use of lead in solder composition has come under scrutiny from environmental factions and has become undesirable in future design applications. As a result, attempts have been made to overcome the use of lead from solder compositions. Such lead-free solder compositions include tin (95% by weight) and antimony (5% by weight) solder compositions. Others include tin, copper and silver (typically 95.5% by weight tin, 4% by weight copper and 0.5% by weight silver) or tin, antimony, zinc and silver (typically 95% by weight tin, 3% by weight antimony, 1.5% by weight zinc and 0.5% by weight silver). Bismuth may also be used together with tin, antimony and silver in a range of approximately 1.0% to 4.5% by weight. Patents directed to lead-free alloys include U.S. Pat. Nos. 1,437,641, 3,607,253, 4,042,725, 4,170,472, 4,667,871, 4,670,217, 4,695,428, 4,758,407, 4,778,733, 4,806,309, 4,879,096, 4,929,423, 5,094,813, 5,102,748, 5,147,471, 5,242,658, 5,256,370, 5,316,205, 5,320,272, 5,328,660, 5,344,607, 5,352,407, 5,390,080, 5,393,489, 5,405,577, 5,411,703, 5,414,303, 5,429,689, 5,435,968, 5,439,639, 5,452,842, 5,455,004, 5,527,628, 5,538,686, 5,569,433, 5,580,520, 5,658,528, 5,698,160, 5,718,868, 5,730,932, 5,733,501, 5,755,896, 5,762,866, 5,817,194, 5,837,191, 5,843,371, 5,851,482, 5,863,493, 5,874,043, 5,918,795, and 6,231,691; European Patent Documents EP-A-0 251 611, EP-A-0 336 575, EP-A-0 629 463, EP-A-0 629 464, EP-A-629 465, EP-A-629 466, and EP-A-629 467; Great Britain Patent Document GB-A-2,158,459; Japanese Patent Documents JP-A-5050286, and JP-A-8230598; and International Patent Publication WO-A-94/2563 the disclosures of each of which are hereby expressly incorporated herein by reference. 
     The invention provides a lead-free solder paste which does not have the disadvantages noted above and is more suitable for use under aggressive conditions as required when using lead-free solders. 
     SUMMARY OF THE INVENTION 
     According to one aspect, the present invention provides a lead-free solder paste comprising a solder paste flux and solder alloy particles that are substantially lead-free wherein the solder paste flux comprises resin dissolved in a solvent and also includes undissolved resin particles less than 25 μm in size homogenously dispersed therein to provide improved solder alloy powder coalescence and substrate surface wetting while maintaining appropriate solder paste rheology for use in printed circuit board assembly processes. 
     According to a further aspect the present invention provides a method for the manufacture of a lead-free solder paste wherein the solder paste flux has two or more resins comprising the steps of dissolving the more soluble resin in part of the solvent and cooling the resultant solution to about 40° C. to 70° C., adding a dispersion of the less soluble resin made in the remainder of the solvent to the cooled solution and adding a gelling agent and allowing the mixture to cool and mixing with lead-free solder alloy particles. 
     The gelling agent is added under controlled temperature and shear conditions and the mixture is then allowed to cool. Mixing is achieved with a high-speed emulsifier that provides the necessary shear and the final temperature during mixing is dependent on the solvent and gelling agent combination but is typically in the range 50° C. to 70° C. 
     Some of the resin initially dissolved also crystallises out of solution on cooling. The finished flux therefore contains (a) resin dissolved (b) resin originally dissolved but now dispersed as solid (c) resin added as a dispersion. 
     According to a still further aspect, the present invention provides a method for reducing the plasticisation of resin by solvents during reflow in a lead-free solder paste wherein the solder paste flux comprises resin and solvent which in addition to resin dissolved in the solvent also includes undissolved resin homogenously dispersed in the solvent. 
     It has been found according to the present invention that if the solder paste flux resin is chosen so that some of the resin is undissolved in the solvent system there is a significant improvement in the wetting and surface appearance of the solder joint in an aggressive reflow process. This results in the solder paste flux solvent being substantially insoluble in the resin melt during the reflow process so that the plasticising effect is significantly reduced. The lead-free solder paste according to the invention shows resistance to aggressive reflow processes without the need for high levels of activators that may compromise the electrical reliability of the residues and without compromising printing performance and storage stability. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     FIG. 1 depicts a temperature-time profile for solder reflow of a lead free solder paste. 
     FIG. 2 depicts a conventional temperature-time profile for solder reflow of a tin-lead solder paste. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The lead-free solder paste flux used in the solder paste according to the invention must include a proportion of the resin which is undissolved in the solvent. This may be achieved by using a solder paste flux resin which is sparingly soluble in the solvent so that some of the resin is in solution and some is not. Alternatively a blend of two or more resins can be used one of which is more soluble in the solvent than the other. In order that the solder paste produced using the flux of this invention can be used in practical application processes, it is necessary to ensure that it has a suitable rheology. Dispersing particles of undissolved resin in the solder paste flux usually has the effect of increasing the viscosity of the flux and the resulting solder paste so that it is unsuitable for application to a printed circuit board by conventional printing or dispensing processes. To overcome this problem, the particle size of the dispersed resin in the solder paste flux of this invention must be less than 25 μm and preferably in the range 5 μm to 15 μm. 
     The solder paste flux according to the invention may be made by initial dissolution of all the resin components in the solvent blend under conditions of vigorous mixing and at temperatures sufficiently high to dissolve the resin. Preferably the temperature is from about 70° C. to 120° C., most preferably about 95° C. A high shear dispersing mixer may be used. By controlling the cooling rate of the flux, it is possible to control the size of the crystals of the resin that are formed. This method is particularly suitable when a single sparingly soluble resin is used. An alternative method used involves the use of two or more resins and involves dissolving the more soluble resins and flux activator chemicals in part of the solvent blend, and allowing it to cool to about 40° C. to 70° C., preferably about 60° C. Preferably 80 to 90% of the solvent may be used if the more soluble resin is 80 to 90% of the total resin content of the final. At this stage, some of the more soluble resin may crystallise from solution. Further undissolved resin is then added as a dispersion of the less soluble resin in the remainder of the solvent. Gelling agents can then be added to the mixture of resin solution and dispersed solution, which is then heated and sheared and cooled to create a solder paste flux of the correct rheology. For example, a modified hydrogenated castor oil wax may be vigorously stirred into the mixture with an emulsifier up to a peak temperature of 70° C. Other gelling agents and solvent combinations require different peak temperatures in the range of about 20° C. to 80° C. 
     The resultant resin particles remain stable in the flux during the subsequent manufacturing steps and also remain stable when the completed solder paste is stored prior to use in the reflow process. Although the sparingly soluble resins do not dissolve in the solvent in the solder paste flux, they are mutually soluble in the other resins. Consequently after PCB reflow, the residues are homogenous and behave like resin in conventional solder paste formulations. 
     The resin used in the solder paste flux may be rosin based, neutral or weakly acidic, or may be a synthetic resin. Preferably, the resin particles are the same size or smaller than the solder particles (20 to 45 μm in common solder pastes). 
     Activators used in the solder paste fluxes include weak carboxylic acids, amines and amine hydrohalide salts which include alkyl and cycloalkyl amines and aromatic amines and the hydrohalide salts of such amines. For example acids such as malonic acid, salicylic acid, adipic acid, succinic acid; amines such as diethylamine, triethylamine, cyclohexylamine, N-methylaniline and their corresponding hydrohalides such as triethylamine hydrobromide. 
     Organic solvents used in the solder paste fluxes include monohydric alcohols, for example, terpineol, and esters, for example, 2-ethoxyethyl acetate. Such solvents have a relatively low melting point and a boiling point below the soldering temperature, and have low moisture absorption. These solvents may be blended with high molecular weight alcohols, polyhydric alcohols such as glycol, for example diethylene glycol, dipropylene glycol or hexylene glycol, or hydric esters, for example triethylene glycol monethyl ether or tetraethylene glycol dimethyl ether, provided that the blend has the aforementioned qualities. 
     Gelling or thickening agents used in the solder paste flux may be ones used in conventional solder paste fluxes such as, for example, ethylcellulose hydrogenated castor oil, fumed silica, or organoclays. Combinations of two or more gelling agents may also be present in the solder paste flux. 
     Preferably tin-rich compositions based on combinations of Sn(Ag)(Cu)(Bi)(Sb) are used. The preferred solder alloy consists of about 3-4% silver and about 0.5 to 1.0% copper, remainder tin, melting at 217° C. This alloy is the lead-free solder with the lowest melting point that has eutectic melting characteristics, i.e., melts at a single temperature with no pasty range. It has good soldering characteristics and is gaining world-wide acceptance as the first choice lead-free solder. Other alloys containing additions of bismuth, zinc, or indium have lower melting temperatures but also have significant pasty ranges, and have significant processing and reliability issues. 
     In a preferred embodiment according to the present invention there is provided a solder paste wherein the solder paste flux comprises from about 1 to about 60% soluble rosin, from about 1 to about 60% insoluble rosin, such that the total resin content of the flux is in the range of from about 40 to about 90% and preferably from about 50 to about 80%, from about 0.1 to about 35% activator, from about 10 to about 50% solvent and from about 0.1 to about 5% thickening agent. 
     Preferably, the solder paste comprises from about 70 to about 92% by weight of the lead-free solder alloy particles, from about 8 to about 30% by weight of the solder paste flux containing from about 50 to 80% resins, from about 20 to 50% solvents, from about 0.1 to 5% activators, and from about 0.1% to about 5% by weight of a gelling agent. 
     The invention is illustrated by the following examples. The following tests and protocols were used in the examples. 
     Acid Value Test 
     The industry-standard method of acid value determination described in IPC TM-650 Method 2.3.13 was used for all the raw materials and the results are expressed as mg KOH/g total flux based on the formulation. 
     Halide Value Test 
     The industry-standard method of acid value determination described in IPC TM-650 Method 2.3.33 was used for all the raw materials and the results are expressed as equivalent chloride concentration as % of total flux based on the formulation. 
     Solder Paste Formulations 
     The finished solder paste was manufactured in each example by mixing 88% by weight solder powder with 12% by weight solder paste flux. The solder powder was lead-free used was SnAg3.8Cu0.7 atomised to produce essentially spherical particles predominantly in the particle size range 20-45 μm. Other alloys, include SnAg3.6, SnCu0.7 and similar tin-rich compositions based on combinations of Sn(Ag)(Cu)(Bi)(Sb) also show improved reflow behaviour with the fluxes described in this invention. Other powder particle sizes and metal contents appropriate to the printed circuit board assembly process may also be formulated with the fluxes described in this invention. 
     Reflow Soldering 
     Solder paste was printed onto a conventional printed circuit board. The metallisation on the PCB was copper. Reflow was carried out in a Seho FDS 6440 3.6 oven using either air as the atmosphere or nitrogen to give a residual oxygen content of less than 150 ppm. The temperature/time profile used is shown in FIG.  1 . 
     Table 1 shows the range of quality that can be obtained on reflow of a solder paste. 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                 Rank 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                   
                 Solder Surface Description 
               
               
                   
                 Bad 
                 Complete non-coalescence 
               
               
                   
                   
                 Fillet surface covered with non-coalesced 
               
               
                   
                   
                 solder 
               
               
                   
                   
                 Fillet surface partly covered with non- 
               
               
                   
                   
                 coalesced solder 
               
               
                   
                   
                 Non coalescence at fillet ends only 
               
               
                   
                 Good 
                 Complete coalescence 
               
               
                   
                   
                 Solder Wetting Description 
               
               
                   
                 Bad 
                 No wetting 
               
               
                   
                   
                 Poor wetting, extensive de-wetting or non- 
               
               
                   
                   
                 wetting 
               
               
                   
                   
                 Fair pad coverage. Some non-wetting or de- 
               
               
                   
                   
                 wetting, fillet edges may be uneven due to 
               
               
                   
                   
                 non-wetting of pad edges 
               
               
                   
                   
                 Good pad coverage, edges/ends of pads have 
               
               
                   
                   
                 some bare copper, fillet has good edge shape, 
               
               
                   
                   
                 no de-wetting or significant non-wetting. 
               
               
                   
                 Good 
                 Almost complete pad coverage (all of pad 
               
               
                   
                   
                 except corners) 
               
               
                   
                   
               
             
          
         
       
     
     COMPARATIVE EXAMPLE 1 
     Tin-Lead Alloy Reflow 
     The solder particle used in conventional reflow conditions is a tin-lead alloy. FIG. 2 shows a conventional time/temperature reflow profile for a tin-lead solder (SN62 or SN63 solder paste). Starting from ambient, the paste is heated to 150° C. at about 60° C./min, and then from 150° C. to a peak reflow temperature of 217° C. at about 85° C./min. The solder is above its melting point for about 45 seconds. From the peak at 217° C. the solder is cooled at about 140° C./min to 80° C. 
     EXAMPLE 1 
     Solder paste flux formulations 1A, 1B and 1C were made in accordance with Table 2 and illustrate the effect of changing from a single resin that is all in solution (1A) to a single resin that is only partially in solution (1B and 1C). Factors contributing directly to flux activity are held constant in formulations 1A, 1B, and 1C. The results are shown in Table 3. The proportions of the resin in solution/out of solution were approximately 100/0 for 1A, 75/25 for 1B and 50/50 for 1C. 
     
       
         
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
           
               
                   
                 TABLE 2 
               
               
                   
                   
               
               
                   
                 RAW MATERIAL 
                 WT % 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 1A: CONVENTIONAL FORMULATION 
               
             
          
           
               
                   
                 Dimerised rosin (Resine K10, 
                 62.6 
               
               
                   
                 Granel S. A.) 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine hydrobromide 
                 0.58 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 30 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Modified hydrogenated castor 
                 5 
               
               
                   
                 oil 
               
             
          
           
               
                 1B: EQUIVALENT FORMULATION 
               
               
                 BUT WITH RESINS NOT IN SOLUTION 
               
             
          
           
               
                   
                 Partially hydrogenated rosin 
                 62.6 
               
               
                   
                 (Staybelite Resin-E, Hercules 
               
               
                   
                 B. V.) 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine hydrobromide 
                 0.58 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 30 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Modified hydrogenated castor 
                 5 
               
               
                   
                 oil (Univar plc) 
               
             
          
           
               
                 1C: EQUIVALENT FORMULATION BUT WITH RESINS NOT IN 
               
               
                 SOLUTION 
               
             
          
           
               
                   
                 Disproportionated gum rosin 
                 62.6 
               
               
                   
                 (Resarim B300, Resitec) 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine hydrobromide 
                 0.58 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 30 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Modified hydrogenated castor 
                 5 
               
               
                   
                 oil (Univar plc) 
               
               
                   
                   
               
             
          
         
       
     
     
       
         
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 3 
               
             
             
               
                   
                   
               
               
                   
                 VALUE/COMMENTS 
               
             
          
           
               
                 PROPERTY 
                 EXAMPLE 1A 
                 EXAMPLE 1B 
                 EXAMPLE 1C 
               
               
                   
               
               
                 Flux 
                 Viscous 
                 Viscous 
                 Viscous 
               
               
                 Appearance 
                 solution 
                 solution 
                 solution 
               
               
                   
                   
                 with 
                 with 
               
               
                   
                   
                 homogeneous 
                 homogeneous 
               
               
                   
                   
                 distribution 
                 distribution 
               
               
                   
                   
                 of resin 
                 of resin 
               
               
                   
                   
                 particles 
                 particles 
               
               
                 Flux Activity 
               
               
                 Acid Value 
                 109.3 
                 109.9 
                 113.0 
               
               
                 Halide Value 
                  0.45 
                  0.45 
                  0.45 
               
               
                 Solder Paste 
               
               
                 Reflow 
               
               
                 Nitrogen 
                 Bright 
                 Bright shiny 
                 Bright shiny 
               
               
                 Atmosphere 
                 shiny 
                 solder 
                 solder 
               
               
                   
                 solder 
                 surface 
                 surface 
               
               
                   
                 surface 
               
               
                 Air Atmosphere 
                 Complete 
                 Non 
                 Fillet 
               
               
                   
                 non- 
                 coalescence 
                 surface 
               
               
                   
                 coalescence 
                 at fillet 
                 partly 
               
               
                   
                 Poor 
                 ends only. 
                 covered with 
               
               
                   
                 wetting 
                 Good pad 
                 non- 
               
               
                   
                 extensive 
                 coverage, 
                 coalesced 
               
               
                   
                 de-wetting 
                 edges/ends 
                 solder. 
               
               
                   
                 or non- 
                 of pads have 
                 Fair pad 
               
               
                   
                 wetting 
                 some bare 
                 coverage. 
               
               
                   
                   
                 copper, 
                 Some non- 
               
               
                   
                   
                 fillet has 
                 wetting or 
               
               
                   
                   
                 good edge 
                 de-wetting, 
               
               
                   
                   
                 shape, no 
                 fillet edges 
               
               
                   
                   
                 de-wetting 
                 may be 
               
               
                   
                   
                 or 
                 uneven due 
               
               
                   
                   
                 significant 
                 to non- 
               
               
                   
                   
                 non-wetting 
                 wetting of 
               
               
                   
                   
                   
                 pad edges 
               
               
                   
               
             
          
         
       
     
     EXAMPLE 2 
     Solder paste flux formulations 2A and 2B were made in accordance with Table 4 which illustrate the effect of partially substituting a resin that is completely in solution (2A) by one that is not completely in solution (2B). Factors contributing directly to flux activity are held constant in formulations 2A and 2B. The results are shown in Table 5. The proportions of the resin in solution/out of solution were approximately 100/0 for 2A, 75/25 for 2B. 
     
       
         
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
           
               
                   
                 TABLE 4 
               
               
                   
                   
               
               
                   
                 RAW MATERIAL 
                 WT % 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 A: CONVENTIONAL FORMULATION 
               
             
          
           
               
                   
                 U.S. Gum rosin 
                 60 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine hydrobromide 
                 0.58 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 12.6 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Tri-propylene glycol n-butyl 
                 20 
               
               
                   
                 ether (Dow) 
               
               
                   
                 Modified hydrogenated castor 
                 5 
               
               
                   
                 oil 
               
             
          
           
               
                 B: EQUIVALENT FORMULATION BUT WITH RESINS 
               
               
                 NOT IN SOLUTION 
               
             
          
           
               
                   
                 U.S. Gum rosin 
                 30 
               
               
                   
                 Partially hydrogenated rosin 
                 30 
               
               
                   
                 (Staybelite Resin-E, Hercules 
               
               
                   
                 B. V.) 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine hydrobromide 
                 0.58 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 12.6 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Tri-propylene glycol n-butyl 
                 20 
               
               
                   
                 ether (Dow) 
               
               
                   
                 Modified hydrogenated castor 
                 5 
               
               
                   
                 oil (Univar plc) 
               
               
                   
                   
               
             
          
         
       
     
     
       
         
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 5 
               
             
             
               
                   
                   
               
               
                   
                 VALUE/COMMENTS 
               
             
          
           
               
                   
                 PROPERTY 
                 EXAMPLE 2A 
                 EXAMPLE 2B 
               
               
                   
                   
               
               
                   
                 Flux Appearance 
                 Viscous solution 
                 Viscous solution 
               
               
                   
                   
                   
                 with homogeneous 
               
               
                   
                   
                   
                 distribution of 
               
               
                   
                   
                   
                 resin articles 
               
               
                   
                 Flux Activity 
               
               
                   
                 Acid Value 
                 106.9 
                 106.3 
               
               
                   
                 Halide Value 
                  0.45 
                  0.45 
               
               
                   
                 Solder Paste 
               
               
                   
                 Reflow 
               
               
                   
                 Nitrogen 
                 Bright shiny 
                 Bright shiny 
               
               
                   
                 Atmosphere 
                 solder surface 
                 solder surface 
               
               
                   
                 Air Atmosphere 
                 Fillet surface 
                 Non coalescence at 
               
               
                   
                   
                 covered with non- 
                 fillet ends only. 
               
               
                   
                   
                 coalesced solder. 
                 Fair pad coverage. 
               
               
                   
                   
                 Fair pad coverage. 
                 Some non-wetting 
               
               
                   
                   
                 Some non-wetting 
                 or de-wetting, 
               
               
                   
                   
                 or de-wetting, 
                 fillet edges may 
               
               
                   
                   
                 fillet edges may 
                 be uneven due to 
               
               
                   
                   
                 be uneven due to 
                 non-wetting of pad 
               
               
                   
                   
                 non-wetting of pad 
                 edges. 
               
               
                   
                   
                 edges 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 3 
     Solder paste flux formulations 3A and 3B were made in accordance with Table 6 and also illustrate the effect of partially substituting a resin that is completely in solution by one that is not completely in solution. Factors contributing directly to flux activity are held constant in examples 3A and 3B. The results are shown in Table 7. The proportions of the resin in solution/out of solution were approximately 100/0 for 3A, 75/25 for 3B. 
     
       
         
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
           
               
                   
                 TABLE 6 
               
               
                   
                   
               
               
                   
                 RAW MATERIAL 
                 WT % 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 A: CONVENTIONAL FORMULATION (Same as 1A) 
               
             
          
           
               
                   
                 Dimerised rosin (Resine K10, 
                 62.6 
               
               
                   
                 Granel S. A.) 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine hydrobromide 
                 0.58 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 30 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Modified hydrogenated castor 
                 5 
               
               
                   
                 oil 
               
             
          
           
               
                 B: EQUIVALENT FORMULATION BUT WITH RESINS 
               
               
                 NOT IN SOLUTION 
               
             
          
           
               
                   
                 Partially hydrogenated rosin 
                 50 
               
               
                   
                 (Staybelite Resin-E, Hercules 
               
               
                   
                 B. V.) 
               
               
                   
                 Fully hydrogenated rosin 
                 12.6 
               
               
                   
                 (Foral AX-E, Hercules) 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine hydrobromide 
                 0.58 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 30 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Modified hydrogenated castor 
                 5 
               
               
                   
                 oil (Univar plc) 
               
               
                   
                   
               
             
          
         
       
     
     
       
         
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 7 
               
             
             
               
                   
                   
               
               
                   
                 VALUE/COMMENTS 
               
             
          
           
               
                   
                 PROPERTY 
                 EXAMPLE 3A 
                 EXAMPLE 3B 
               
               
                   
                   
               
               
                   
                 Flux Appearance 
                 Viscous 
                 Viscous 
               
               
                   
                   
                 solution 
                 solution with 
               
               
                   
                   
                   
                 homogeneous 
               
               
                   
                   
                   
                 distribution of 
               
               
                   
                   
                   
                 resin particles 
               
               
                   
                 Flux Activity 
               
               
                   
                 Acid Value 
                 109.3 
                 110.5 
               
               
                   
                 Halide Value 
                  0.45 
                  0.45 
               
               
                   
                 Solder Paste Reflow 
               
               
                   
                 Nitrogen Atmosphere 
                 Bright shiny 
                 Bright shiny 
               
               
                   
                   
                 solder surface 
                 solder surface 
               
               
                   
                 Air Atmosphere 
                 Complete non- 
                 Complete 
               
               
                   
                   
                 coalescence. 
                 coalescence. Good 
               
               
                   
                   
                 Poor wetting, 
                 pad coverage, 
               
               
                   
                   
                 extensive de- 
                 edges/ends of pads 
               
               
                   
                   
                 wetting or non- 
                 have some bare 
               
               
                   
                   
                 wetting 
                 copper, fillet has 
               
               
                   
                   
                   
                 good edge shape, 
               
               
                   
                   
                   
                 no de-wetting or 
               
               
                   
                   
                   
                 significant non- 
               
               
                   
                   
                   
                 wetting. 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 4 
     Formulations 4A and 4B were made in accordance with Table 8 which illustrate the effect of partially substituting a resin that is completely in solution by one that is not completely in solution. In this case, additional levels of activator have been used to illustrate that the resin out of solution adds to the effect produced by increasing activator level. Factors contributing directly to flux activity are held constant in examples 4A and 4B. The results are shown in Table 9. The proportions of the resin in solution/out of solution were approximately 100/0 for 4A, 55/45 for 4B. 
     
       
         
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
           
               
                   
                 TABLE 8 
               
               
                   
                   
               
               
                   
                 RAW MATERIAL 
                 WT % 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 A: CONVENTIONAL FORMULATION 
               
             
          
           
               
                   
                 U.S. Gum rosin 
                 60 
               
               
                   
                 Malonic acid 
                 0.53 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine 
                 0.4 
               
               
                   
                 hydrobromide 
               
               
                   
                 Meso-2,3-dibromosuccinic 
                 0.7 
               
               
                   
                 acid 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 12 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Tri-propylene glycol n- 
                 20 
               
               
                   
                 butyl ether (Dow) 
               
               
                   
                 Modified hydrogenated 
                 5 
               
               
                   
                 castor oil 
               
             
          
           
               
                 B: EQUIVALENT FORMULATION BUT WITH RESINS NOT IN 
               
               
                 SOLUTION 
               
             
          
           
               
                   
                 U.S. Gum rosin 
                 28.5 
               
               
                   
                 Hydrogenated rosin (KE612, 
                 28.5 
               
               
                   
                 Arakawa) 
               
               
                   
                 Partially hydrogenated 
                 4.7 
               
               
                   
                 rosin (Staybelite Resin-E, 
               
               
                   
                 Hercules B. V.) 
               
               
                   
                 Malonic acid 
                 0.6 
               
               
                   
                 Salicylic acid 
                 1.0 
               
               
                   
                 Trans-2,3-dibromo-2-butene- 
                 0.3 
               
               
                   
                 1,4-diol 
               
               
                   
                 2-bromoethylamine 
                 0.4 
               
               
                   
                 hydrobromide 
               
               
                   
                 Meso-2,3-dibromosuccinic 
                 0.7 
               
               
                   
                 acid 
               
               
                   
                 Di-ethylene glycol di-butyl 
                 12.0 
               
               
                   
                 ether (Grant Chemical) 
               
               
                   
                 Tri-propylene glycol n- 
                 19 
               
               
                   
                 butyl ether (Dow) 
               
               
                   
                 Modified hydrogenated 
                 4.8 
               
               
                   
                 castor oil (Univar plc) 
               
               
                   
                   
               
             
          
         
       
     
     
       
         
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 9 
               
             
             
               
                   
                   
               
               
                   
                 VALUE/COMMENTS 
               
             
          
           
               
                   
                 PROPERTY 
                 EXAMPLE 4A 
                 EXAMPLE 4B 
               
               
                   
                   
               
               
                   
                 Flux Appearance 
                 Viscous solution 
                 Viscous solution 
               
               
                   
                   
                   
                 with homogeneous 
               
               
                   
                   
                   
                 distribution of 
               
               
                   
                   
                   
                 resin particles 
               
               
                   
                 Flux Activity 
               
               
                   
                 Acid Value 
                 109.8 
                 113.3 
               
               
                   
                 Halide Value 
                  0.45 
                  0.45 
               
               
                   
                 Solder Paste 
               
               
                   
                 Reflow 
               
               
                   
                 Nitrogen 
                 Bright shiny 
                 Bright shiny 
               
               
                   
                 Atmosphere 
                 solder surface 
                 solder surface 
               
               
                   
                 Air Atmosphere 
                 Fillet surface 
                 Non coalescence at 
               
               
                   
                   
                 covered with non- 
                 fillet ends only. 
               
               
                   
                   
                 coalesced solder. 
                 Fair pad coverage. 
               
               
                   
                   
                 Fair pad coverage. 
                 Some non-wetting 
               
               
                   
                   
                 Some non-wetting 
                 or de-wetting, 
               
               
                   
                   
                 or de-wetting, 
                 fillet edges may 
               
               
                   
                   
                 fillet edges may 
                 be uneven due to 
               
               
                   
                   
                 be uneven due to 
                 non-wetting of pad 
               
               
                   
                   
                 non-wetting of pad 
                 edges. 
               
               
                   
                   
                 edges