Application Note AN-0994 Maximizing the Effectiveness of your SMD Assemblies Table of Contents Page Method ....................................................................2 Thermal characteristics of SMDs..............................2 Adhesives ...............................................................4 Solder pastes..........................................................4 Reflow profiles ........................................................4 Rework ...................................................................6 Maximizing Effectiveness of SMD Assemblies www.irf.com AN-0994 Version 6, May 2012 Page 1 of 6 calibration table to estimate Tj. The temperature rise due to the heating pulse was calculated using this equation: Introduction This application note describes the measurement of thermal resistance for International Rectifier’s surfacemounted devices (SMDs). It explains how packages were mounted and the techniques used in heat sinking and testing. It applies only to SMDs, not to throughhole devices such as TO-220, TO-247 and Fulpak. ΔT = Temperature difference (C) between junction temperature and reference temperature (TJ - TRef); TRef is the ambient, package case or package lead temperature Method RTH = Thermal resistance (C/W) between junction and reference point (package case or package lead) ΔT = RTH X PD where: PD = Power dissipated (W) Standard printed circuit boards were developed, to which the devices under test were solder-mounted for measuring thermal resistance. The boards measured 4.75 inches by 4.5 inches, and were made of FR-4 backed with 2 oz copper. We can calculate the thermal resistance by inserting measured values of temperature rise and power. Measurements were taken from representative samples of all the packages listed in Table 1. Note: A specific thermal test board was used for DirectFET because of this package’s unique connection design. Thermal characteristics of SMDs Three metal patterns were tested (Figure 1): one square inch of copper modified minimum: copper covered only the space occupied by the device and lead pads minimum pattern: copper covered only the space occupied by the lead pads. Table 1 shows typical and maximum Rth (JA) and typical Rth (JL) values of International Rectifier’s SMD packages mounted using the metal patterns shown in Figure 1. For Rth (JC) values, refer to the appropriate data sheet. Modified minimum pattern One square inch pattern Minimum pattern The device was placed in the middle of the pads shown. Figure 1 Device placement used in testing Notes In accordance with industry practice, thermal resistance was measured by first performing a reference temperature estimate. A temperature sensitive electrical parameter (TSEP) such as Vsd was measured and compared with a calibration value to determine the junction temperature (Tj). A heating pulse of known power was then applied. This was followed by a second TSEP measurement, which was compared with a Maximizing Effectiveness of SMD Assemblies www.irf.com Table 1 Typical and maximum thermal resistance Package type Thermal resistance One Modified Minimum All square inch minimum Typ Max Typ Max Typ Max Typ Rth(JA) Rth(JA) Rth(JA) Rth(JA) Rth(JA) Rth(JA) Rth(JL) D-Pak 20.2 26.3 42.0 54.6 59.5 77.3 2.0 D2-Pak 18.0 23.3 33.6 43.7 36.7 47.7 1.6 SO-8 33.5 50.0 66.3 86.2 70.6 91.8 10.6 SO-8 (dual) 54.5 62.5 73.1 95.1 94.7 123.1 28.7 SOT-223 27.2 60.0 49.0 63.7 66.1 86.0 4.9 TSOP6 (dual) 73.4 125.0 134.7 175.1 170.7 222.0 35.5 TSOP6 (single) 47.3 62.5 112.0 145.6 118.5 154.0 17.0 TSSOP8 60.9 83.0 106.4 138.3 117.0 152.1 35.5 u-3 169.2 230.0 237.1 308.2 263.6 342.6 139.3 u-6 47.1 75.0 112.5 146.3 124.9 162.4 14.7 u-8 39.9 70.0 102.4 133.2 126.1 163.9 17.0 DirectFET A specific thermal test board was used because of DirectFET’s unique connections. This table is split to reflect this difference but, to improve readability, the results are shown together on the following graphs. Small can 32.1 60.0 49.2 64.0 68.1 88.5 NA Medium can 32.3 60.0 55.6 72.3 62.2 80.9 NA 1. Three pieces of each package type were in the sample. 2. Rth (JL) (typical) and R th (JL) (one square inch) were measured at the same time (Rth reference to drain lead). 3. Measurement conditions were as described in Method. 4. The board contributes greatly to the total thermal resistance. If its material properties or dimensions vary significantly from those used by International Rectifier, actual thermal resistance may vary. AN-0994 Version 7, August 2012 Application Note Page 2 of 6 Using the Max Rth (JA) values from Table 1, Figures 2 to 4 plot power dissipation against ambient temperature for each metal pattern. Larger packages with exposed heat sinks (such as D2-Pak, D-Pak and SOT-223) usually have the highest power dissipation capabilities. Increasing the area of the metal pattern reduces the thermal resistance. The measurements taken using the three different pattern areas reflect this, with the one square inch pattern giving the lowest resistance. Figure 3 Ambient power dissipation – modified minimum Figure 2 Ambient power dissipation – one square inch Maximizing Effectiveness of SMD Assemblies www.irf.com Figure 4 Ambient power dissipation – minimum AN-0994 Version 7, August 2012 Application Note Page 3 of 6 Adhesives vendor and board fabricator for recommendations specific to their application. As the connections on an SMD do not pass through the board on which it is mounted, such devices rely solely on the strength of the solder joint for mechanical as well as electrical connection. Reflow profiles Many assemblies require devices to be mounted on both sides of the board. The reflow process is typically done only once, with both sides of the board pasted at the same time. Devices are placed on one side of the board, using an adhesive to hold them in place, and then the board is turned through 180 degrees for devices to be placed on the other side. The board is subjected to a thermal process to melt the solder paste. When the devices have been soldered to the board, the adhesive serves no further purpose. The adhesive used must secure the devices to prevent movement during handling and soldering. However, it must be possible to break the bond with minimal disturbance to the populated board so that incorrectly positioned devices can be moved before soldering. Adhesion must be maintained during preheating and the adhesive should not interfere with solder flow during the reflow or wave soldering process. Typical adhesives of this type are made from nonactivated resins (R), which can be used in a forming gas atmosphere to reduce oxides. Some are mildly activated resin (RMA), which can be used in normal factory environments. The activators in these resins dissolve small amounts of oxidation from solderable surfaces and solder particles in the paste. Solder pastes A wide range of solder pastes is available for surface mounting applications. Typically, they are composed of a homogeneous mixture of pre-alloyed solder powder with a specific grain size. Fluxes are included, as they are essential to the surface mounting process. In today’s densely populated assemblies, the leads on SMDs are significantly closer together. Spacing of less than 0.4mm is common and it can cause problems such as solder bridging, insufficient solder on leads and inaccurate device placement. The stencil’s thickness, dimensions and registration accuracy and the solder paste’s composition and particle size are all critical in soldering these assemblies successfully. Given these complexities, advising on the choice of solder paste is beyond the scope of this application note. Customers should contact their solder paste Maximizing Effectiveness of SMD Assemblies www.irf.com A major problem associated with mounting SMDs, especially those with mismatched internal expansion coefficients, is the thermal shock of the soldering process. The advent of lead-free assemblies has driven the requirement to develop and implement new handling techniques for SMDs. Lead-free solders typically have higher melting points than traditional lead-based solders. Where lead-based assemblies could be mounted at peak reflow temperatures in the range 220°C to 245°C, lead-free assemblies require temperatures in the range 245°C to 260°C. Higher peak temperatures require careful control of the reflow environment to prevent over-temperature conditions that can severely degrade the reliability of SMDs. Caution must be taken when choosing a reflow profile to optimize the thermal stresses that are applied to the assemblies, whether lead-based or lead-free. Conversely, under-temperature conditions can result in failed mechanical attachment. A carefully controlled pre-heat and post-cooling sequence is necessary. Properly controlling the preheat cycle removes any volatile components of the solder paste, such as alcohol or water, by evaporation before the solder fusing cycle starts. This reduces the chances of forming voids or solder balls. Table 2 shows critical parameters of the reflow profile. Table 2 Critical parameters by solder paste and device volume Profile feature Lead-free3 Lead-based All sizes Large Small body1 body2 Average ramp-up rate, 3 3 3 TL to Tp (°C/sec max) Preheat 150 100 100 Temp min, Tsmin (°C) 200 150 150 Temp max, Tsmax (°C) 60–180 60–120 60–120 Time, Tsmin to Tsmax (sec) Max ramp-up rate, Tsmax to TL 3 — — (°C/sec) Time maintained above: 217 183 183 Temp, TL (°C) 60–150 60–150 60–150 Time, tL (sec) 260 +0/-54 225 +0/-5 240 +0/-5 Peak temperature, Tp (°C) 10–30 10–30 Time within 5°C of actual peak 10–30 temperature, tp (sec) 6 6 Max ramp-down rate (°C/sec) 6 8 6 6 Max time 25°C to peak temperature (min) AN-0994 Version 7, August 2012 Application Note Page 4 of 6 Notes: 1. Large Body: TO-220, D2pak and larger (package 3 thickness ≥2.5 mm or package volume ≥ 350 mm ) 2. Small Body: Dpak, Ipak and smaller (package thickness 3 < 2.5 mm or package volume < 350 mm ) 3. Lead-free devices have the suffix PbF in the part number. To check if a device is lead-free, contact the sales representative or the factory. 4. The recommended peak reflow temperature for some large-body packages (such as PLCC-44 / MQFP64) is 250°C +0/-5°C. To check the peak temperature for a device, contact the sales representative. This thermal conditioning can be applied in several ways, including infrared/convection reflow, vapor phase reflow and wave soldering. Figures 5 and 6 show recommended profiles for infrared/convection reflow and wave soldering. Table 3 and Table 4 give recommendations for specific SMDs. temperature ramp up tp TP ramp down TL tL TSmax TSmin tspreheat t25ºC to peak time Figure 5 Infrared / convection reflow profile temperature 10±1 sec *Tpeak Table 3 Infrared/convection reflow recommendations Package Reflow temp (°C) Name Size Lead-free Lead-based D2PAK L 250 225 D-61-8 L 250 225 D-PAK S 260 245 Micro-3/SOT 23 S 260 245 Micro-6/SOT 6 S 260 245 Micro-8 S 260 245 MLP-20 4x4 S 260 245 MLP-28 5x5 S 260 245 MLP-48 7x7 S 260 245 MLP-6 3x3 S 260 245 MQFP64 L 250 225 PDIP-14 L 250 225 PDIP-16 L 250 225 PDIP-20 L 250 225 PDIP-28 L 250 225 PDIP-8 L 250 225 PLCC44 L 250 225 SMA S 260 245 SMB S 260 245 SMC S 260 245 SOICN-14 S 260 245 SOICN-16 S 260 245 SOICN-8 S 260 245 SOICW-16 S 260 245 SOICW-20 S 260 245 SOICW-28 S 260 245 SOT223 S 260 245 TO-220 L 250 225 TO-247 L 250 225 TO-262 L 250 225 TSSOP20 S 260 245 TSSOP24 S 260 245 TSSOP8 S 260 245 Thickness > 2.5 mm or volume > 350 mm2, reflow 250+0/-5°C (Pbfree), 225+0/-5°C (SnPb eutectic) Thickness < 2.5 mm and volume < 350 mm2, reflow 260+0/-5°C (Pb-free), 240+0/-5°C (SnPb eutectic) Disclaimer: 1st wave 150−200ºC / sec 2nd wave 5ºC / sec If you attach packages using wave solder immersion, you may need to make special evaluations because of Tpeak 1st wave ≤ 10ºC of Tpeak differences in the process 2ºC / sec 140ºC 25ºC 1.5 sec time 80 sec 100 sec Figure 6 Wave soldering profile Maximizing Effectiveness of SMD Assemblies www.irf.com 200 sec Table 4 Wave solder recommendations Package Reflow temp (°C) D2PAK 225 D2PAK 260 DPAK 260 D-PAK 235 SOICN-14L 240 SOICN-14L 260 SOICN-16L 260 SOICN-28L 240 SOICN-8L 240 SOICN-8L 260 SOICW-16L 240 SOICW-16L 260 * Contact manufacturer for more information AN-0994 Version 7, August 2012 Remarks Not lead-free Lead-free Lead-free* Not lead-free* Not lead-free Lead-free Lead-free Not lead-free Not lead-free Lead-free Not lead-free Lead-free Application Note Page 5 of 6 Rework When replacing an SMD that has been soldered onto a substrate, the main problem is applying enough heat to melt all the connections on the device that is being rep laced without overheating adjacent devices. This is achieved by using a soldering iron with a specially shaped tip and, because of the diversity of SMD package styles, a corresponding variety of tips is required. The tip must have a gripping function so that, when the solder is reflowed, the device can be extracted from the board. When the replacement SMD is mounted, the tool must perform the reverse procedure. Flux must be applied to the new device before localized reflow. Maximizing Effectiveness of SMD Assemblies www.irf.com AN-0994 Version 7, August 2012 Application Note Page 6 of 6