Contrast-Infused Solder Material for PCB Residue Detection
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Solution Overview
Problem
Existing solder flux residue on printed circuit boards (PCBs) negatively impacts the functionality and reliability of high-reliability electronics, necessitating accurate identification and removal.
Innovation Solution
Infusing solder materials with a contrast agent that enhances residue visibility through radiographic imaging, allowing for precise detection and confirmation of residue removal using x-ray or CT scanning systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solder flux is used in the soldering process, then the soldering process can remove metal oxides and aid in wetting, but residue remains behind that negatively impacts functionality and reliability
Solution Approach 1:
The contrast agent is added to the solder flux before the soldering process, enabling preliminary marking of the flux application areas. This allows the residue to be pre-identified and tracked through subsequent cleaning processes, resolving the contradiction by maintaining the necessary flux application while enabling reliable detection of remaining residue that could impact electronics functionality
2Device complexity
If residue is not detected, then the inspection process is simple, but the residue can cause corrosion and lead to failure of electronics
Solution Approach 1:
The contrast agent causes the flux residue to appear with enhanced contrast in radiographic images, enabling visual differentiation between residue and clean areas. This transforms the inspection process from complex multi-step procedures to simpler radiographic imaging that can clearly identify residue locations, thereby preventing corrosion and electronic failure while maintaining inspection simplicity
3Ease of operation
If conventional inspection methods are used, then the inspection process is straightforward, but residue beneath electrical components cannot be accurately identified
Solution Approach 1:
The contrast agent acts as an intermediary substance that enhances the visibility of flux residue in radiographic images. By introducing this intermediate element, the inspection system can accurately detect residue beneath electrical components through radiographic imaging, achieving both ease of operation and high measurement precision simultaneously
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables effective identification and removal of solder flux residue, ensuring the reliability and functionality of electronic assemblies by highlighting residue in radiographic images, thereby preventing corrosion and failure.
Implementation Method 1
The contrast agent can be used to increase the contrast within residues under or near electrical components of the PCB by absorbing or changing the way that electromagnetic radiation passes through such residues on the PCB when scanned using radiographic imaging
Data Source
AI summary
An electrical connection material having a contrast agent infused within, and related systems and methods of detection thereof, are disclosed herein. Computer electronics such as printed circuit boards have electronic components attached to a substrate by an electrical connection material. The electrical connection material has at least one component infused with a contrast agent. The contrast agent is of a concentration to provide a visual distinction or highlight when imaged by an inspection system, such as an x-ray system of computed tomography (CT) scanning system. The presence of the contrast agent demonstrates that not all of residual electrical connection material has been cleaned away from the printed circuit board after manufacture.