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As the parts become smaller and closer together, this number naturally goes up A second assembly measure is average leads (I/Os) per square inch or square centimeter This is the x-axis value multiplied by the y-axis value (For a further description of these issues, and equations for quantifying them, see Chap 18) The z-axis oval in Fig 22 describes the printed wiring board s density This is the wiring required to connect all the I/Os of the components at the size of the assembly specified, assuming three nodes per netThis axis has the units inches per square inch, or centimeters per square centimeter A further description of this metric is provided in this chapter and in more detail in Chap 19 22.

3 An Example of the Interconnect Revolution By charting products of a particular type over time, an analysis will show how the interconnect technology has changed and continues to change, its rate of change, and the direction of these changes An example is given in Fig 23 This shows how component technology, assembly technology, and PWB technology have led to the evolution of the same computer CPU from:.

1 Single-sided (top side), surface-mount only: a Print paste b Place components c Reflow solder paste 2 Double-sided, surface-mount only: a Bottom side, print paste b Bottom side, dispense adhesive for larger components, if necessary c Bottom side, place components d Bottom side, reflow solder paste and cure adhesive Flip the board over to the top side: e Top side, print paste f Top side, place components g Top side, reflow solder paste 3 Double-sided, mixed technology (with bottomside wave soldering): a Bottom side, dispense adhesive for surface-mount components b Bottom side, place surface-mount components c Bottom side, cure adhesive Flip the board over to the top side: d Top side, print paste f Top side, place components g Top side, reflow solder paste h Top side, insert through-hole components Keep the top side facing up: i.

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Wave-solder the through-hole and the bottom-side surface-mount components In case (3), for mixed-technology products, there is some flexibility regarding the sequence of staking (gluing) of bottomside components versus the topside soldering step, based largely upon the capabilities of the pick-and-place equipment In the case of area-array packaging technology having solder balls (BGA, CSP, and DCA), there is the option of not adding solder paste to the pads Instead, only the flux is deposited on the pads, which serves to tack the package in place during transport of the board to the reflow oven The solder balls provide the solder to complete the joint; however, the penalty is a reduced gap thickness that may affect self-alignment during soldering (as well as solder-joint reliability later on).

Omitting the solder paste is most often considered for the DCA/FC assembly process because the solder balls, and the corresponding pads, are so small that it is not possible to print the acceptable quantity and dimensions of the paste consistently There is also the use of step-solder processes for double-sided, surface-mount-only circuit boards, that is, case (2) A high-temperature solder, often the 965 Sn-35 Ag (Sn-Ag) alloy (Teutectic = 221 C), is used to attach the bottomside components These solder joints do not remelt when the topside joints are made using the Sn-Pb solder (Teutectic = 183 C) Somewhat tighter process control is required, since the 221 C Sn-Ag eutectic temperature is very near the optimum, peak process temperature for the Sn-Pb process (210 220 C).

This approach provides the option of placing larger passive and active components on both sides of the circuit board without the need for an adhesive dispensing and curing step Unfortunately, the use of the higher melting temperature, Pb-free Sn-Ag-Cu solders all but eliminates this step-soldering approach without identifying a higher melting temperature solder for the first step The following sections examine each of the steps in a surface-mount assembly process, beginning with an examination of component types The different dispensing technologies are reviewed, including those for solder paste and adhesives Component placement machines are examined, followed by a description of the use of the various heat sources such as convection/radiation reflow ovens, wave-soldering equipment, condensation reflow apparatus, hand soldering, and conduction soldering Lastly, cleaning processes are described..