Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt...
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Transcript of Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt...
![Page 1: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/1.jpg)
Aerosol Jet® Printing of A Silver Epoxy Conductive Adhesive for High Density
Applications
Kurt Christenson and Michael Renn - Optomec, Inc.
Donald Giroux - Resin Designs, LLC
Daniel Blazej - Assembly Answers, LLC
IMAPS New England SymposiumBoxborough, MA
May 8, 2012
![Page 2: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/2.jpg)
May 8, 2012 IMAPS New England Symposium Page 2
Who Are The Players?• Optomec - Equipment Company Based In
Albuquerque, NM Focused On Additive Manufacturing– LENS (Laser Engineered Net Shaping) 3D Printer– Aerosol Jet® Printer
• Resin Designs - Adhesives Company In Woburn, MA Producing Custom Formulations For Many Electronic and Industrial Applications
• Assembly Answers - Manufacturers Representative Providing Sales and Marketing Services For Resin Designs
![Page 3: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/3.jpg)
May 8, 2012 IMAPS New England Symposium Page 3
Drivers for Collaboration
• Identified Needs For Conductive Adhesive That Can Be:– Dispensed In Small Volumes, Creating Dots 0.001” - 0.002” In
Diameter For Small Components and Thin Bond Lines– Dispensed In Recessed Areas And On Different Height
Substrates With Non-Contact Nozzle, Standoff Up To 1 cm– Used For Bonding Small Devices Requiring High Electrical and
Thermal Conductivity
• Push “Pixel Density” from ~100 DPI To ~1000 DPI And From 2D to 3D
![Page 4: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/4.jpg)
May 8, 2012 IMAPS New England Symposium Page 4
Optomec Aerosol Jet Technology
• Material Aerosolized and Mixed With Carrier Gas In Atomizer
• Aerosol Concentrated In Virtual Impactor And Excess Gas Removed
• Material Stream Exits At Deposition Head And Patterns Created With Shutter (Not Shown)
![Page 5: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/5.jpg)
May 8, 2012 IMAPS New England Symposium Page 5
Aerosol Jet Process Movie
Video May Also Be Seen Here
![Page 6: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/6.jpg)
May 8, 2012 IMAPS New England Symposium Page 6
Aerosol Jet Is Not Ink Jet!
![Page 7: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/7.jpg)
May 8, 2012 IMAPS New England Symposium Page 7
Unique Dispense Technology Needs Unique Adhesive Technology
• Silver Particles Need To Be Nanometer Sized– Conventional Die Attach Adhesives
Use Multimicrometer Sized Particles
• Silver And Resins Must Maintain Homogeneous Distribution In Micrometer Sized Droplets
• Resins Must Be Stable For Processing And Long Work Life
Conventional Silver PasteParticle Size Distribution Before and After Aerosol
Jet Deposition
![Page 8: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/8.jpg)
May 8, 2012 IMAPS New England Symposium Page 8
Development Challenges
• Epoxy System Selected As Core Adhesive– Critical Modifications Made Over Course Of Project
• Separation Of Silver and Resin In Aerosol An Early Stumbling Block– Overcome With Modifications To Both Silver and Resin– Important To Understand How Aerosol Is Created And
Maintained
• Maintaining Stoichiometry of Resin and Hardener In Aerosol Is Critical For Optimum Properties
![Page 9: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/9.jpg)
May 8, 2012 IMAPS New England Symposium Page 9
Aerosolizing Adhesive!
• Collison Nebulizer Creates Aerosol– Carrier Gas @ 20 PSI Aspirates Liquid
Suspension of Silver and Resins– Spray Is Directed Onto Wall of Jar– Small Drops Recoil, Producing Aerosol
That Exits Through Outlet Tube
• Silver Adhesive System Designed To Stay Intact Through This Process– Choice Of Solvent Is Critical
![Page 10: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/10.jpg)
May 8, 2012 IMAPS New England Symposium Page 10
Printing Adhesive• Test Pattern Is 10 x 10 Array Of 10 mil (250 µm)
Squares– Thickness Range Is 10 - 30 µm– Built Up From Individual Drops <5 µm In Diameter– Cross Section Is Isosceles Trapezoid
Not:
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May 8, 2012 IMAPS New England Symposium Page 11
Producing A Single Square
QuickTime™ and aJVT/AVC Coding decompressorare needed to see this picture.
Click On Each Picture To See Video (May Not Show On All Systems)
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May 8, 2012 IMAPS New England Symposium Page 12
Process / Handling Characteristics
• High Velocity Jet (100 m/sec) Precisely Places Adhesive– Solvent Removal Facilitated With Heated
Substrate At 60°C
• Cure 60 Minutes @ 150°
• Work Life > 1 Week
• Store 6 Months @ -10°C
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May 8, 2012 IMAPS New England Symposium Page 13
Electrical Properties• Five Line Patterns On Alumina Substrate• Line Width = 130 µm, Height = 15 µm• Cured 60 Minutes @ 150°C• Linear Response, Resistivity = 5 x 10-5 Ω-cm
0
5
10
15
20
25
30
35
40
45
0 2 4 6 8 10 12 14 16
Line Length (cm)
Resistance (ohms)
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May 8, 2012 IMAPS New England Symposium Page 14
Adhesion Properties
• Lap Shear Between Aluminum Plates Is 2000 PSI
• Die Shear Of 15 Mil Tabs On Gold Is 3000 PSI
• Cohesive Failure In All Cases• Comparable To Standard Die
Attach Epoxies• Meets MIL-STD-883, Method
2019 Requirement of 882 PSI• Tg ~ 100°C
15 mil Square Kovar Tab On Needle Dispensed
Nanoparticle Silver Epoxy
![Page 15: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/15.jpg)
May 8, 2012 IMAPS New England Symposium Page 15
Technical Status
• Basic Formulations Established For Aerosol Jet and Narrow Gauge Needle Dispense– Minor Modifications For Handling Optimization May Occur
• Additional Characterization In Process– Thermal Conductivity
• Expecting High Value Based On High Silver Content
– Storage Modulus– Ionic Content– Outgassing– CTE– Work and Storage Life
![Page 16: Aerosol Jet ® Printing of A Silver Epoxy Conductive Adhesive for High Density Applications Kurt Christenson and Michael Renn - Optomec, Inc.Optomec, Inc.](https://reader031.fdocuments.in/reader031/viewer/2022012922/56649e755503460f94b76413/html5/thumbnails/16.jpg)
May 8, 2012 IMAPS New England Symposium Page 16
Summary• New Conductive Adhesive Material Developed For Use
With Novel, Non-Contact Dispense Technology– Significant Benefits Realized In Creating Small Features With
Laser-Like Control On Varying Height Surfaces– Unique Adhesive Characterized By High Loading Of Nanoparticle
Silver In Epoxy Resin
• Optomec Aerosol Jet Systems Are Commercially Available– Applications Lab In Minnesota For Customer Support
• Resin Designs Nanoparticle Silver Epoxies Available For Sampling– Aerosol Jet– Narrow Gauge Needle
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May 8, 2012 IMAPS New England Symposium Page 17
Company Links and E-Mail
• Resin Designs, LLC: www.resindesigns.com– Don Giroux: [email protected]
• Optomec, Inc.: www.optomec.com– Kurt Christenson: [email protected]– Mike Renn: [email protected]
• Assembly Answers, LLC: www.assemblyanswers.com– Dan Blazej: [email protected]