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MEMS are characterized by miniaturization, multiplicity and microelectronics Figure 83 shows the comparative sizes of MEMS devices The three characteristics of a MEMS device can be clearly seen from the example of the inertial sensors The conventional inertial sensor system is shown in Figure 84, whereas the comparison with micromachined system is shown in Table 81 Table 81 clearly indicates the superiority of a micromachined system in terms of size, cost and function The reduction in size tends to give many advantages A smaller system has a lower inertia of mass enabling the system to move more quickly Since the resonant vibration of a system is inversely proportional to the mass, microsystems are less prone to thermal distortion and vibration In addition, miniaturization allows for stable, more accurate and precision performance for application in the field of medicine, surgery, satellites, spacecraft engineering and telecommunication systems [6]

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The Reflow Profile There are four distinct steps in the reflow profile that must be accommodated by the reflow oven for successful soldering. Each step must be tailored for the solder paste composition and must be accomplished in proper, controllable, and repeatable reflow equipment. A misstep at any of the four stages of reflow can result in product loss. Refer to Fig. 47.8 for this discussion on thermal profile.

FIGURE 47.8 Schematic of a generic reflow profile for Sn-Ag-Cu solder paste. Time-temperature values are not precise and are shown for illustrative purposes for a discussion of reflow soldering.

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47.3.5.1 Initial Ramp. In this step of the reflow time-temperature profile, preheating of the boards, components, and solder paste is initialized. The solder paste begins to lose some of its volatile components and the flux becomes chemically active (activates). If the ramp gradient is too steep, volatiles will be given up too rapidly, boiling will result, and the solder paste will spatter. This can cause explosive solder ball formation and decrease local solder volume, and thus impair bond reliability. Unattached solder balls may form solder bridges between two closely spaced conductors and produce an electrical short circuit. Overly rapid heating is known to cause component cracking. This is particularly true of ceramic components.To be safe, restrict the ramp rate to between 2 to 4 C/sec., but investigate component manufacturers specifications as well as the solder paste vendor s recommendation for the maximum allowable heating ramp.

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47352 Thermal Soak During this step, the solder, board, and components are further heated The flux from the solder paste flows onto all metal surfaces in which it is in contact, continues to react away surface oxides, and also acts as a barrier to prevent oxidation The soak is designed to provide the requisite time and thermal energy for the flux s prolonged chemical reaction with oxides and tarnishes on metal surfaces and the solder Were the flux to activate fully too early in the process, it could dry out or be spent too soon If its potency is lost, fluxed metal surfaces will reoxidize in the critical moments before the onset of solder liquidus, and solder wetting (alloying) would be inhibited 47353 Spike 473531 Onset of Solder Liquidus.

Microelectro-mechanical Systems (MEMS)

In this step, the solder undergoes a phase change from solid to liquidThe liquid metal solder wets onto fluxed metallic surfaces and flows along the component lead-to-PWB pad interfaces drawn by surface tension, capillary forces, and convective flows within the liquid metal This is the essence of soldering and effective solderjoint formation Characterized by a rapid thermal rise, the spike s peak temperature is chosen to be well above the solder s melting point to ensure that all parts of the board, all components, and all solder paste deposits have surpassed solder liquidus onset As examples, for eutectic Sn-Pb solder, the peak temperature is generally 25 to 40 C above the melting point For Sn-Ag-Cu solders, the peak is a more conservative 15 to 30 C above the onset of liquidus.

For the values illustrated, the RC time constant is 1 ms, and so the capacitor will charge to 25 V in about 720 s Thus the worst-case conversion time by the scheme is 720 s The nonlinearity in the RC charging can be removed with the help of a scheme as illustrated in Figure 614, where the resistor R1 is replaced with a transistor current source A constant current source will charge the capacitor linearly, and so the accumulated count will be linearly proportional to the input-applied voltage on the Ain-pin With the values illustrated in Figure 614, the current sourced by the PNP transistor is about 80 A.

The lower temperature overage for SAC solder as compared to Sn-Pb is due to the higher melting range of the SAC alloy family and the potential damage to components and the circuit board due to the higher-temperature regime needed for reflow Also, since the temperature is higher than for SnPb, oxidation of heated metal surfaces is more likely, as is solder paste decomposition or charring 473532 Surface Tension Effects While the solder is molten, surface tension effects draw component leads into best registration with circuit board pads if the component is light enough to float upon the molten solder Passive devices (resistors, capacitors, inductors, etc), most components with formed leads, and plastic or laminate BGAs self-align during this step.

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