Polymerizable Flux Composition for Encapsulating the Solder in Situ

This invention relates to the field of adhesive technology, and in particular, to the field of isotropic, electrically conductive adhesives.

The standard method of joining and interconnecting electronic components is soldering with eutectic tin-lead (SnPb) solder in the presence of a fluxing agent. Conventional SnPb solder technology was invented over 5,000 years ago and is increasingly at odds with current manufacturing requirements. The problems with conventional solder technology originate in the high temperatures required, the reflow properties of solder, and the environmental impact of solder and solder fluxes.

Conventional SnPb solder requires temperatures of 200.degree. C. or more for reflow. These temperatures can damage delicate circuit components, and the printed circuit boards (PCBs) on which components are mounted must be made of relatively expensive, heat resistant materials. The high reflow temperatures used can also cause "popcorning", where moisture is explosively released from heated solder and PCBs, creating cracks in standard solder joints. In addition, mounting devices on PCBs with conventional SnPb technology is complicated by the reflow properties of solder. In order to attach components to the bottom side of the PCB, components must be preliminarily attached to the PCB with a dot of adhesive, and the adhesive cured. The adhesive prevents components on the bottom side of a PCB from falling off when components on the top side of the board are soldered in place. Expensive machines called "dot shooters" deposit dots of adhesive, before the components are placed on the PCB.

The environmental problems created by conventional solder technology are attributable to both the toxicity of Pb and the composition and post-soldering treatment of fluxes. Following reflow, conventional solder fluxes must be washed off circuit boards with cleaning fluids, and the cleaning fluids containing flux residues subsequently enter the environment. Previously, the cleaning fluids of choice were chlorofluorocarbons (CFC), which are ozone depleting compounds (ODC). ODCs are currently being phased out in favor of non-ODC cleaners and new, no-clean, low residue solders that do not require cleaning have been developed.

While these developments are positive, they do not eliminate the environmental problems associated with conventional solder technology. For example, ordinary fluxes contain 50 to 65% solvent. These solvents are volatile organic compounds (VOC) which evaporate during the soldering process and enter the atmosphere. No-clean solders use fluxes comprising 20% solids and 80% VOCs. Thus, while no-clean solvents reduce the need for cleaning solvents, they increase the level of pollution attributable to VOCs. In addition, no clean solders typically require inert atmospheres for reflow.

An emerging alternative to standard solder technology uses isotropic electrically conductive adhesives (ICAs) comprising conductive metal particles, often silver, dispersed in a polymerizable matrix. The two component composition of ICAs allows their electrical and mechanical properties to be tailored independently for a particular application. ICAs can be cured at temperatures as low as 130.degree. C. This eliminates damage to heat sensitive components, allows the use of lower cost PCB substrates, and eliminates "popcorning", which does not occur at the lower processing temperatures of ICAs. In addition, the lower processing temperatures of ICAs eliminates the need for dot shooters and the associated manufacturing steps.

Currently available ICAs have found only limited use, because the adhesive-to-metal joint they form is substantially weaker and more susceptible to corrosion than the metallurgical bond created by soldering. ICA joints do not survive a mechanical shock test that is consistently passed by conventional solder joints. In this test, developed by the National Center for Manufacturing Sciences (NCMS) and aptly called the "drop test", a plastic leaded chip carrier (PLCC) having 44 J-shaped leads is mounted to pads on a PCB and dropped from a height of 5 feet six times. None of the currently available ICA joints survive the drop test.

With regard to corrosion, the adhesive-to-metal joints formed by ICAs are susceptible to degradation in elevated humidity/temperature conditions (85.degree. C., 85% relative humidity). Under these conditions, oxygen diffuses into the ICA joints, causing oxidation and corrosion. The resulting ICA joints are unstable and their electrical and mechanical performance is unreliable. The electrical instability may be reduced through the use of oxide penetrating particles, but this does not improve the ICA joint's performance in the drop test.

This present invention is a polymer-based solder paste composition that combines the strength and corrosion resistance of joints produced by conventional solder technology with the environmental and processing advantages of ICA technology. In its unreacted state, the solder composition is a paste comprising a metal powder and a single component (single package) polymerizable flux composition. Upon heating, the metal powder spontaneously segregates from the flux composition, fuses, and forms a metallurgical joint. The single component polymerizable flux composition encapsulates the fused metal in a polymer coating which remains firm but pliable at reflow temperatures. The polymer coating holds the soldered article in place while allowing rework of the soldered joint if necessary.

A solder composition in accordance with the present invention comprises a fusible, solderable metal alloy and a polymerizable, crosslinkable, thermosetting composition polymer formulation which acts as a fluxing agent and adheres to the molten metal while it is being cured. Applied heat melts the metal particles, which fuse as a result of the fluxing action. The resin then encapsulates the fused metal and cures as a solid polymer film on the surface of the fused metal. Polymerization of the single component epoxy formulation is triggered by application of heat, unlike the two part epoxies that require a chemical initiator to initiate polymerization.

In one embodiment of the present invention, the polymer formulation includes polymerizable monomers, a dibasic organic acid, a polyalcohol (polyols), and a curing agent. In addition, the formulation preferably includes a chelating agent, defoamer, thixotrope and surfactant. Several modifications of this formulation allow for a decrease in its final viscosity.

The monomer is an epoxy or a mixture of epoxies, and the dibasic organic acid is a dicarboxylic acid, which reacts with the epoxy to enhance cross-linking and also acts as the primary fluxing agent. Two-function polyalcohols (diols) dissolve the acid, promote the acid's fluxing action, and chemically react with the epoxy. An amine curing agent promotes fluxing action, and also acts as surfactant and promotes wetting between the polymer and the molten solder. In selected cases, the dibasic acid component may be omitted from the formulation, in which case the fluxing action is provided by the amine and polyol components.

The chelating agent extends pot life and gel time of the composition by scavenging metal ions that are formed by the action of the acid and that promote copolymerization of the organic diacid and epoxy if allowed to accumulate. The chelating agent also promotes the adhesion of the polymer film to the molten metal surface during cure by chelating metal ions formed as a result of the fluxing process. The defoamer promotes the release of air and gas bubbles formed during melting of the metal, reducing the incidence of voids and "popcorning". When necessary, a surfactant is used to improve wetting of the molten metal surface and a thixotrope modifies the viscosity of the flux to make the composition more suitable for fine pitch printing by reducing sag and settling.

In a second embodiment of the present invention, which is particularly useful in lower viscosity applications, the polymer formulation includes polymerizable monomers, a liquid organic acid, and a curing agent. If additional reduction in viscosity is desired, solvents and a defoaming agent may be included as necessary. The monomer is an epoxy or a mixture of epoxies, and the liquid organic acid is a carboxy-acrylate, which can react with either epoxy or acrylate groups to enhance cross-linking and also acts as the primary fluxing agent. An amine curing agent promotes fluxing action, and also acts as surfactant and promotes wetting between the polymer and the molten solder.

The properties of the metal powder employed in the solder composition can be chosen independently of the polymer formulation and fitted to the application. For example, an indium-tin eutectic alloy (52In48Sn, hereinafter InSn) melting at 118.degree. C. may be used for low temperature applications (130.degree. C. to 150.degree. C.). For most other applications, the conventional tin-lead eutectic (63Sn37Pb, hereinafter SnPb) which melts at 183.degree. C. is used. Choices of most other ingredients are dictated by the processing temperature and processing time requirements.

The polymerizable flux of the present invention provides a metallurgical solder joint without the many deleterious environmental effects associated with fluxes, cleaning agents, and solvent evaporation in conventional soldering fluxes. In addition, problems related to solder joint failure caused by thermo-mechanical stresses and amplified by voids created by evaporating solvents are eliminated. Encapsulation of the solder joint by a polymer film makes it possible to use this material as a die attach adhesive, eliminating the need for dot shooters and the extra processing steps associated with their use. The solder composition provides a conductive joint that passes the drop test, and results in a stable junction under elevated temperature/humidity conditions, as required by most transportation, aerospace and military applications.

In order to appreciate the advantage of the present invention, an overview of the joint formation process is provided for the case of a SnPb alloy processed at a temperature of 200.degree. C. for 3 minutes. Over the 3 minute heating period, the following processes occur:

a. Heat is transferred to the solder and the polymer formulation.

b. The solder particles melt.

c. The polymer formulation viscosity drops resulting in a low viscosity liquid.

d. Oxides on the surface of the solder particles are dissolved by the fluxing action and the particles sinter to form a continuous fused metal.

e. The polymer formulation is squeezed out to the surface of the fused solder.

f. The polymer formulation gels and cures in situ on the surface of the molten metal.

Typically step (a) takes about 30 seconds. Steps (b), (c) and (d), which are approximately concurrent, take place in the next 30 seconds. The fluxing action occurs primarily in this 30 second period, during which time the polymer formulation has to remain a low viscosity liquid in order to ensure that the metal sinters and fuses properly. Over the next 2 minutes, the polymer cures and creates a continuous solid film covering the surface of the still molten metal.

When the ingredients are properly formulated, the solder composition will perform all these processes in the allotted time intervals. The acid component of the polymeric formulation is the principal fluxing agent, but it is aided by the polyol component, when employed, and the curing agent, when the latter is an amine. The gel time and cure are controlled primarily by the amine curing agent and the epoxy, but are also influenced by the organic acid and chelating agent used. The wetting and surface activity of the formulation prevent the polymeric material from dewetting (rolling off) the surface of the molten metal and forming into drops.

Steps similar to (a)-(f) occur in processes using InSn alloys for the metal component. In theses case, however, the lower melting point of the InSn eutectic allows the processes to be run at 150.degree. C. Since there is no danger of heat damage to electronic components at this lower processing temperature, a 10 minute heating cycle may be used. The lower temperature and longer cycle time are more forgiving and allow a broader choice of components for the polymeric formulation.

For purposes of the present invention, the term solder metal refers to any of the standard solder metals and alloys. Examples of solder metals suitable for use in the present invention are those provided in Indalloy Specialty Solders & Alloys (1988), a product catalog published by the Indium Corporation of America

The solder compositions in accordance with the present invention do not create residues that must be cleaned from the soldered joint. For example, two samples prepared with the solder composition of the present invention were placed in an extraction apparatus following a three minute cure. One sample was extracted with boiling water for 8 hours, and the other sample was extracted with boiling tetrahydrofuran (THF) for 8 hours. Despite the harsh conditions, less than 2% by weight of the polymerized material was extracted by the water, and typically only about 1.4% was extracted. This is less than the total residue produced by low residue and no-clean solders. The electrical resistance of the extract water was also measured to determine the level of extracted corrosive, ionic residue, in conformance with accepted military specifications (MIL-P-28809). Measured resistances were typically greater than 200 K.OMEGA., indicating that substantially no residue had been removed from the polymerized solder joint. In the first alternative embodiment of the present invention the measured resistances were >>1 M.OMEGA..

Extraction with THF provides an indication of the relative amounts ofpopolymer in the sol and gel phases, with the gel phase being preferred extraction indicates that approximately 50% to 70% of the polymer is in the insoluble gel phase following a three minute cure. Higher proportions of gel phase would be expected following longer cure times.

Solder compositions in accordance with the first embodiment of the present invention greatly reduce the amount of VOCs generated by soldering. For example, the polyols included as a solvent for the dicarboxylic acids and to promote fluxing, have boiling points of >200.degree. C. They do not evaporate at typical reflow temperatures but rather react with the epoxy component, as discussed below. Consequently, VOCs evolved by the soldering composition either during or following soldering are minimized. The weight loss of the polymer formulation during cure at 200.degree. C. is about 8% based on the polymer. In contrast, standard commercial fluxes lose approximately 50 to 80% of their total weight as volatile organic compounds that evaporate from the flux material.

Components soldered with the formulation of the present invention do not move in consecutive reflow cycles because they are held in place by the polymer coating generated on heating. Surface mounted components can be reflowed while upside down without falling off the PCB. The polymer coating, which is hard at room temperature, retains its binding strength to the PCB at the reflow temperature but is sufficiently pliable to make reworking the junction possible.

Available ICAs, while providing comparable bonding at elevated temperatures, do not produce the strong, stable, corrosion resistant joints provided by compositions in accordance with the present invention. Drop tests performed on PCBs including joints made with a polymerizable flux in accordance with the present invention failed to dislodge soldered components. The drop tests were repeated after placing the PCBs in a reflow oven with the components facing down, and no failures were produced at any time.

In the present invention, the polymerizable flux formulation contains crosslinkable monomers such as epoxides. Among the epoxides, epoxy novolacs provide the highest degree of polymerization and crosslinking because of their high functionality. Functionality is defined as the number of epoxide units per molecule, which in the case of epoxy novolacs is between approximately 3 and 4.

The viscosity of the polymeric composition increases with increasing functionality of the epoxy, and the degree of crosslinking has to be balanced against the fluxing ability of the composition, which is favored by lower viscosity. For example, a balance may be obtained between high functionality and low viscosity by mixing an epoxy novolac with a lower viscosity, two-function epoxy or diepoxide. Among the diepoxides, the most useful are the diglycidyl ethers of bisphenol A and bisphenol F. The latter usually offer a similar performance to the diglycidyl ethers of bisphenol A but has a lower viscosity. For purposes of this discussion, low viscosities are those in the range of about 10-300 centipoise (cps), low/medium viscosities are in the range of about 300-2000 cps, medium viscosities are between about 2,000-5,000 cps, and high viscosities are anything greater than about 5,000 cps.

Illustrative of the epoxies used in the present invention are Dow Epoxy Novolac DEN 438 (DEN 438) mixed with Ciba-Geigy's Araldite PY 306 (PY 306), a Diglycidyl Ether of Bisphenol F (DGEBF). DEN 438 has a functionality of 3.6 and is a semi-solid at room temperature, with a viscosity of about 20,000 to 50,000 cps at 52.degree. C., while PY 306 has a functionality of 2.0 and a viscosity of 1,500 cps at 25.degree. C. In one embodiment employing DEN 438 and PY306, a mixture of 2 parts by weight of DEN 438 and 1 part PY 306 is used to give an average functionality of 3.0.

Also suitable as an epoxy component for the present invention is Shell Chemical's Epon SU 2.5, which is 70% Epon 828, a Diglycidyl Ether of Bisphenol A (DGEBA), and 30% epoxy novolac with high functionality. Epon 828 has an average functionality of 2.1 and a viscosity of 13,000 cps at 25.degree. C. Epon SU 2.5 has an average functionality of 2.5 and viscosity of 20,000 cps at 25.degree. C. Another epoxy composition suitable for the polymeric resin formulation is Ciba-Geigy's Araldite CY 184, a diglycidyl ester of hexahydrophthalic (1,2-cyclohexanedicarboxylic) anhydride with a viscosity of 900 cps at 25.degree. C. The cross-linking provided by this epoxy is not as extensive as that provided by DEN 438/PY306 or EPON SU 2.5. However, CY184 does have a relatively low viscosity and good adhesion to the molten solder, since it may chelate the metal ions in the process of polymerization. Cyracure UVR 6105, a 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexane produced by Union Carbide and having a viscosity of 230 cps, may be added to these epoxy formulations when needed to reduce viscosity. Similarly, Heloxy 68, a two functional epoxy, with viscosity of 13 cps at 25.degree. C., is a reactive diluent that may be added to the above epoxies to reduce the viscosity of the polymer composition.

Additional alternative embodiments of the present invention may employ UV curable epoxy-acrylate combinations. These are advantageous in cases where high crosslinking is desired and the junctions are accessible to UV radiation. Examples of epoxy acrylate combinations are Ebecryl 3800, a carboxy functional epoxy acrylate made by UCB Radcure Inc. Ebecryl 3800 is a slow reacting, high viscosity, high functionality liquid. It may be combined with 1,6-hexanediol diacrylate (HDODA), a fast reacting, low viscosity liquid (9 cps at 25.degree. C.), or with epoxidized soy bean oil acrylate, a medium viscosity, moderately slow reacting liquid, to produce an epoxy suitable for use in the present invention.

The primary fluxing agents in this embodiment of the present invention are dibasic carboxylic acids, also known as dicarboxylic acids or dioic acids. Dicarboxylic acids are more likely to react with epoxy and produce more extensive crosslinking than monobasic acids. Since dibasic acids have higher functionality (more carboxyl groups per molecule) than monobasic acids, less acid is needed in the formulation. Examples of dicarboxylic acids employed in compositions of the present invention are glutaric acid (pentane dioic acid), adipic acid (hexane dioic acid), azelaic acid (nonane dioic acid), and 1,3-cyclohexanedicarboxylic acid, all of which are solids. A high viscosity liquid such as poly(ethylene glycol)bis(carboxymethyl)ether (PEGBCME) with molecular weight of about 250, may also be used. All dibasic carboxylic acids used in the polymeric formulations described were obtained from Aldrich Chemical Co.

As noted above, the dibasic acid component of the flux may be omitted in selected formulations of this embodiment, in which case the amine curing agent and polyol components provide the flux promoting action. One such case provides high conductivity solder joints by including silver particles with the solder metal and allowing the relatively low melting temperature solder metal to establish electrical contact with the high melting point, highly electrically conductive silver particles when heat is applied. Because silver ions are particularly effective at initiating polymerization in the presence of acids, the dibasic acid component is omitted from the flux, and fluxing action is provided by the combined actions of the amine thermal cure agent and the polyol.

In addition to enhancing the fluxing action, polyfunctional alcohols serve as good, non-volatile (high boiling point) solvents for dicarboxylic acids, when this component is present. Polyols have the further advantage of crosslinking with the epoxy component, but they also have relatively high viscosities. Diols provide a good compromise between cross-linking ability and low viscosity, but a number of lower viscosity triols may be used as well. For example, the diols, ethylene glycol and propane diol, and especially triethylene glycol, diethylene glycol, 1,3 propanediol and 1,2 propanediol, provide a reasonable compromise between cross-linking ability and low viscosity. Polyoxypropylene triols such as Arcol LHT 112 made by ARCO Chemical Co. and polyether triols such as Voranol 230-238 made by Dow Chemical Co. also provide a reasonable balance between cross-linking and low viscosity.

Amines are a very large group of chemically reactive compounds which can act as curing agents for epoxies. Primary and secondary amines directly crosslink with epoxy while tertiary amines act as catalysts to enhance cross-linking among epoxies and hydrogen donating molecules such as hydroxyls and carboxyls. The preferred curing agent is selected from the family of amidoamines. Amidoamines are a product of monobasic carboxylic acids (fatty acids) and aliphatic polyamines. Consequently, they possess amine as well as amide functionalities, in addition to properties imparted by the particular fatty acid used. Witcamine 210, a pasty solid which is made by Witco Corp. and sold as a surfactant, was found to provide particularly good wetting and adhesion between the molten metal and the polymer flux. For 150.degree. C. cure dicyanodiamide (DICY) was used in the form of a fine white powder named Amicure CG-1400 available from Air Products and Chemical Co. Also used was Ancamide 506, a low viscosity liquid also available from Air Products and Chemicals Co. To enhance good through-cure at 200.degree. C., a boron trifluoride-amine complex, Anchor 1040, supplied by Air Products Chemicals, was used.

A number of different chelating agents were found to be useful in the present invention. These include ethylenediamine tetraacetic acid (EDTA) obtained from Aldrich, Irganox MD 1024, a 1,2-bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazine made by Ciba-Geigy, and Naugard XL-1, a 2,2'-oxamido bis-[ethyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] made by Uniroyal Chemical Company. Of these, EDTA is the most commonly used chelating agent but has a very limited solubility. MD 1024 and Naugard XL-1 are both combinations of hindered phenol antioxidant and amide type chelating agents. MD 1024 showed the best compatibility with the present compositions.

For defoaming, Dislon OX-70 was used. This is a polymethacrylate defoamer and wetting agent made by Kusumoto Chemicals of Japan and sold in the U.S. by King Industries. In some formulations of the first alternative embodiment a thixotropic agent, Dislon 6900-20X, was also used. This is a polyamide wax manufactured by Kusumoto Chemicals and sold by King Industries.

The surfactant used in the first alternative embodiment of the invention is Silwet L-77, a mixture of polyalkyleneoxide modified heptamethyltrisiloxane and allyloxypolyethyleneglycol methyl ether, made by OSi Specialties, Inc.

Several modifications to this embodiment of the present invention decrease the viscosity of the polymer flux formulation. A reduction in viscosity can be achieved by the addition of a lower molecular weight diol. For example, 1,3-propanediol has a molecular weight of 76.1 and viscosity of 32.5 cps, measured at 25.degree. C., compared to triethylene glycol, which has a molecular weight of 150.2 and a viscosity of 36.5 cps measured at 25.degree. C. Thus 1,3-propanediol has nearly twice as many hydroxyl residues, based on molecular weight, as triethylene glycol. Additionally, 1,3-propanediol has a lower viscosity, and acts as a more aggressive fluxing agent and crosslinker than triethylene glycol. Therefore, less solid dicarboxylic acid needs to be added to the polymer flux composition when 1,3-propanediol is used, resulting in a polymer formulation with similar fluxing activity but a lower overall viscosity.

Yet another modification of the first embodiment that results in lower viscosity, is to substitute Araldite CY 192-1, a diglycidyl ester of tetrahydrophthalic acid with a viscosity of 500 to 800 cps, or a similar compound, for Araldite CY 184. To increase the crosslink density CY 192-1 can be used in combination with DEN 438 or similar epoxies (see example 20).

The addition of an internal lubricant, such as light mineral oil, further reduces the viscosity of this formulation (see example 21). Light mineral oil, such as Drakeol 7 by Penreco, is only partially miscible with the solder paste formulation and segregates to the surface of the paste as the formulation is applied. After the polymer cures, the light mineral oil, forms an inert waxy coat on the polymer surface.

Alternatively, viscosity can be reduced when an epoxy-anhydride formulation, employing a low viscosity liquid anhydride such as methylhexahydrophthalic anhydride (MHHPA) with a viscosity of 65 cps at 25.degree. C., is used. During the copolymerization process the anhydride monomers are converted to a carboxylic acid which then forms a copolymer with the epoxy monomers. Consequently, the amount of solid dicarboxylic acid added to the formulation for fluxing purposes can be reduced. Traditionally, epoxy-anhydride formulations required either curing at elevated temperatures for several hours or the addition of very aggressive catalysts, resulting in a formulation with a relatively short pot life. Improved epoxy-anhydride catalysts which diminish these problems, such as Ajicure MY-24, supplied by Ajinomoto Chemical Company, are presently available (see example 22).

A second embodiment of the present invention contains a polymerizable flux including polymerizable epoxy or epoxide monomers, a liquid organic acid and a curing agent (see example 23). This embodiment is especially useful for low viscosity applications.

When a combination of low to medium viscosity and high crosslink density are required, it is advantageous to use low to medium viscosity epoxides with low epoxy equivalent weights. Epoxy equivalent weight is defined as the molecular weight divided by the number of epoxy groups per molecule. A suitable low/medium viscosity epoxide with a low epoxy equivalent weight is Araldite MY 0510, a trifunctional epoxide of p-aminophenol with an epoxy equivalent weight of 100 and a viscosity of 550 to 850 cps, enabling it to form densely crosslinked networks.

Further reduction in viscosity is achieved in the second embodiment using a liquid organic acid which enhances epoxy cross-linking and also acts as the primary fluxing agent. Dioic acids, employed in the first embodiment, are solids at room temperature (approximately 25.degree. C.). Substituting organic acids that are liquid at room temperature for dioic acid decreases the final viscosity of another embodiment. Suitable liquid organic acids include some of the carboxy-acrylates, for example, 2-carboxyethyl acrylate (2-CEA), an acrylic acid dimer with a functional carboxyl group at one end and an acrylate group at the other end of the molecule. 2-CEA may react with epoxy or acrylate groups to become incorporated into a crosslinked network. Additionally, acrylic acid polymers are not toxic, in contrast to monomers of acrylic acid. Other members of the carboxy-acrylate group, characterized by the structure: ##STR1## where R is any linear hydrocarbon, may also be useful for low to medium viscosity applications.

2-CEA can be combined with MY 0510 and an amine or amidoamine curing agent, such as DICY, to produce a low or low/medium viscosity polymerizable flux composition. When combined with metal powder in this embodiment of the present invention and heated, this low viscosity polymerizable flux composition forms a hard film over the fused solder metal with strong adhesion properties and a glass transition temperature (T.sub.g) of 130.degree. to 150.degree. C. depending on the cure cycle. Using diaminodiphenylsulfone (DDS) instead of DICY a T.sub.g of up to 200.degree. C. can be achieved.

Low to medium viscosity polymerizable flux compositions may also contain nontoxic, non-ozone depleting solvents with boiling points below the solder reflow temperature, preferably in the range of 140.degree. C. and 180.degree. C. The solvent improves the handling of the polymer-based solder paste composition when stenciled onto PCBs. To improve the handling of the polymer-based solder paste composition, the solvent must reduce the viscosity of the paste, lubricate the metal stenciling blades so the polymer-based solder paste composition will not stick to them, and evaporate slowly at room temperatures so the polymer-based solder paste composition will not dry out while being manipulated. Illustrative of suitable solvents, useful in either embodiment of the present invention, are linear hydrocarbons, such as nonane, decane and mineral spirits; esters, such as isobutyl isobutyrate, methyl lactate and butyl lactate; ether esters, such as ethylene glycol ether acetate and ethylene glycol ethyl ether acetate; and terpenes, such as .alpha.-pinene and limonine (see example 25). These solvents may be used individually or in combination to yield the desired viscosity.

In sum, one embodiment of the polymer flux composition comprises the following components in the indicated percent weight ranges:

Epoxy: 55%-70%

Acid: 0%-15%

Diol: 5%-12%

Amine: 3-5%

Chelate: 4%-6%

Defoamer: 0.5%-1%

Surfactant: 0.5%-1.5%

Thixotrope: 1%-5%

In another embodiment of the present invention, the polymer flux composition comprises the following components in the indicate d percent weight ranges:

Epoxy: 55-70%

Acid: 20-30%

Amine: 4-10%

Examples of some of the compositions produced and tested are presented below. All compositions contain SnPb and are designed for 200.degree. C. cure for 3 minutes in a conventional forced air oven, unless otherwise indicated.

In a container prepare a mixture comprising by % weight: 14% glutaric acid and 14% triethylene glycol. Heat at 130.degree. C. and stir until the glutaric acid dissolves. Add 5% Irganox MD 1024 and reheat while stirring until the latter reaches its limit of solubility. Then remove from the heat, add 23% Araldite CY 184, mix and add 38% of a 2:1 mixture of DEN 438 and Araldite PY 306 and mix thoroughly. Add 1% Dislon OX-70 and 5% Witcamine 210. Mix thoroughly and stir for 20 to 30 minutes at 4,000 RPM. To the polymer formulation thus prepared add SnPb powder to bring the total composition to 88% SnPb and 12% polymer formulation. Stir for 30 minutes at 500 to 1,000 RPM.

The polymer formulation of example 1 in which Witcamine 210 is replaced with 5% Ancamide 506. All other ingredients and mixing procedures are the same.

The polymer formulation of example 1 in which Irganox MD 1024 is replaced with 5% Naugard XL-1. All other ingredients and procedures are the same.

The polymer formulation of example 1 in which Irganox MD 1024 is replaced with 5% EDTA. All other ingredients and procedures are the same.

The polymer formulation of example 1 in which triethylene glycol is replaced by 14% Arcol LHT-112. All other ingredients and procedures remain the same.

The polymer formulation of example 1 in which triethylene glycol is replaced by 14% Voranol 230-238. All other ingredients and procedures remain the same.

The polymer formulation of example 1 in which glutaric acid is replaced with 1,3-cyclohexanedicarboxylic acid. All other ingredients and procedures remain the same.

The polymer formulation of example 1 in which glutaric acid is replaced with 18% adipic acid. Proportions of other ingredients are as follows: 14% triethylene glycol, 5% Irganox MD 1024, 23% Araldite CY 184, 34% mixture of DEN 438/Araldite PY 306, 5% Witcamine 210 and 1% Dislon OX-70. All procedures remain the same.

The polymer formulation of example 1 in which glutaric acid is replaced with 22% azelaic acid. Proportions of other ingredients are as follows: 13% triethylene glycol, 4% Irganox MD 1024, 22% Araldite CY 184, 33% mixture of DEN 438/Araldite PY 306, 5% Witcamine 210, 1% Dislon OX-70. All procedures are the same.

The polymer formulation of example 9 in which azelaic acid is replaced with 22% poly(ethylene glycol)bis(carboxymethyl)ether (PEGBCME). All other ingredients and procedures remain the same.

The polymer formulation of example 1 in which the proportions of ingredients are changed as follows: 15% glutaric acid, 15% triethylene glycol, 15% Araldite CY 184, 40% DEN 438/Araldite PY 306 mixture. Add 4% Dislon 6900-20X. All other ingredients and procedures are the same.

In a container prepare a polymer formulation comprising by % weight: 15% glutaric acid, 10% triethylene glycol, 2% Irganox MD 1024, 10% Araldite CY 184, 28% Araldite PY 306, 25% Epon SU 2.5, 6% Witcamine 210, 0.5% Dislon OX-70 and 3.5% Dislon 6900-20X. All the procedures are the same as in example 1.

Compositions of examples 13 and 14 are UV curable.

In a container prepare a polymer formulation comprising by weight: 15% glutaric acid, 15% triethylene glycol, 56% Ebecryl 3800, 10% 1,6-hexanediol diacrylate (HDODA), 4% benzophenone. Stir for 30 minutes at no more than 1,000 RPM.

Add SnPb powder in the amount to bring the total composition to 88% SnPb and 12% polymer formulation. Stir for 10 minutes at no more than 500 RPM.

The polymer formulation of example 13 in which the amount of Ebecryl 3800 is reduced to 49%, HDODA is replaced by 10% epoxidized soy bean oil acryl ate, and 5% Irganox MD 1024 is added. All other ingredients and procedures are the same as in example 13.

Compositions 15 and 16 contain InSn and are designed for 150.degree. C. cure for 10 minutes in a conventional forced air oven.

In a container prepare a polymer formulation comprising by % weight: 15% glutaric acid, 10% 1,3-propane diol, 30% Cyracure UVR 6105, 30% Araldite PY 306, 5% Amicure CG 1400, 5% Dislon 6900-20X, 5% Silwet L-77. All procedures are the same as in example 1, except SnPb is replaced with InSn.

In a container prepare a polymer formulation comprising by weight: 20% adipic acid, 10% 1,3-propane diol, 35% Cyracure UVR 6105, 20% Araldite PY 306, 10% Amicure CG 1400, 5% Silwet L-77. All procedures are the same as in example 15.

In a container prepare a polymer formulation comprising by weight 15% 1,3-cyclohexanedicarboxylic acid, 10% triethylene glycol, 5% Irganox MD 1024, 32% Araldite CY 184, 32% Epoxy novolac DEN 438, 2% Witcamine 210, 3% Anchor 1040, and 1% Dislon OX-70. The resulting composition yields a resistance of the boiling water extract, performed in accordance with MIL-P-28809 of 5 M.OMEGA., and approximately 75% of the material is not extractable with boiling THF. The resulting viscosity is greater than 8000 cps at 25.degree. C. and a shear rate of 200 sec.sup.-1.

In a container prepare a polymer formulation comprising by weight 15% 1,3-cyclohexanedicarboxylic acid, 10% triethylene glycol, 5% Irganox MD 1024, 29% Araldite CY 184, 29% Epoxy novolac DEN 438, 6% Heloxy 68, 2% Witcamine 210, 3% Anchor 1040, and 1% Dislon OX-70. The resulting composition yields a resistance of approximately 1.5 M.OMEGA. when tested in accordance with MIL-P-28809 and approximately 50% of the material is not extractable in boiling THF. The resulting viscosity is 7900 cps and a shear rate of 200 sec.sup.-1, measured at 25.degree. C.

In a container prepare a polymer formulation comprising by weight 12% triethylene glycol, 6% Irganox MD 1024, 38% Araldite CY184, 25% Cyracure UVR 6105, 10% Heloxy 68, 5% Anchor 1040, 3% Witcamine 210, and 1% Dislon OX70. The resulting composition yields a resistance of approximately 1.9 M.OMEGA. when tested in accordance with MIL-P-28809.

The polymer formulation of example 18 in which the Araldite 184 is replaced with Araldite 192-1. All other ingredients and procedures are the same. The resulting composition yields a flux viscosity, measured at 25.degree. C. and a shear rate of 192 sec.sup.-1 using a cone and plate viscometer, of 3500 cps, compared to 7900 cps for the polymer formulation of example 18. The resulting composition also yields a resistance of approximately 2.0 M.OMEGA. when tested in accordance with MIL-P-28809 and approximately 54% of the material is not extractable in boiling THF.

In a container prepare a polymer formulation comprising by weight 30.5% DEN 438, 30% Araldite 192-1, 10% 1,3-cyclohexanedicarboxylic acid, 10% 1,3-propanediol, 10% Drakeol, 5% Irganox MD 1024, 4% Anchor 1040, and 0.5% Witcamine 210. The resulting composition yields a viscosity of 14,000 cps at a shear rate of 2 sec.sup.-1 and of 1,600 cps at a shear rate of 384 sec.sup.-1, measured at 25.degree. C. The resulting resistance is approximately 1 M.OMEGA.when tested in accordance with MIL-P-28809 and 60% of the material is not extractable in boiling THF.

A polymer-based solder paste composition containing by weight 87% SnPb eutectic alloy metal powder (mesh size between -325 and +500), and 13% of this polymer formulation yields a viscosity of 160,000 cps at a shear rate of 2 sec.sup.-1 and 80,000 cps at a shear rate of 10 sec.sup.-1, when measured at 25.degree. C.

In all previous examples the solder paste viscosity was 10.sup.6 cps or higher at a shear rate of 2 sec.sup.-1 when measured at 25.degree. C.

In a container prepare a polymer formulation comprising by weight: 38% MHHPA, 23.5% Araldite CY 192-1, 9% Cyracure UVR 6105, 9% Heloxy 68, 7.5% 1,3-propanediol, 5% Drakeol, 4.5% Irganox MD 1024, 3% 1,3-cyclohexanedicarboxylic acid, and 0.5% Ajicure MY-24.

A polymer-based solder paste composition prepared as in example 21 yields a viscosity of 78,000 cps at a shear rate of 20 sec.sup.-1 when measured at 25.degree. C.

In a container prepare a polymer formulation comprising by weight: 65% Araldite MY 0510, 25% 2-CEA and 10% DICY. Stir for 30 minutes at 1500 RPM. Add 10-30% decane by weight and stir for a minimum of 5 minutes. The resulting composition, when cured at 200.degree. C. for 5 minutes, yields a T.sub.g of approximately 130.degree. C.

The polymer formulation of example 23 in which DICY is replaced with diaminodiphenyl sulfone. All other ingredients and procedures remain the same. The resulting composition, when cured at 200.degree. C. for 5 minutes, yields a T.sub.g of approximately 160.degree. C. With increased cure times the T.sub.g is increased to approximately 200.degree. C.

In a container prepare a polymer formulation comprising by weight: 26% Araldite CY 192-1, 26% DEN 438, 7% Heloxy 68, 15% 1,3-cyclohexanedicarboxylic acid, 15% 2-methyl 1,3-propane diol, 5% Irganox MD 1024, 5% Anchor 1040 and 1% Witcamine 210. Stir at 3000 RPM for 20 minutes. Add 10-30% by weight a mixture of solvents containing 13 parts decane, 10 parts methyl lactate, 7 parts light mineral oil, 5 parts limonene and 8 parts OX-70 (defoamer) and stir for a minimum of 5 minutes.

Generally, glutaric acid and 1,3-cyclohexanedicarboxylic acid are interchangeable in each of the above-described examples that includes a dicarboxylic acid. However, the 1,3-cyclohexanedicarboxylic acid may provide better wetting between the polymer formulation and the molten metal.

Performance standards for die attach adhesives collected from various references indicate that the dominant concerns of ICA manufacturers/users are adhesion and stable contact resistance. The consensus from the surveyed references appears to be that the minimum die shear strength should exceed 1000 psi and preferably be over 2000 psi after each environmental test, mechanical shock, or vibration. The compositions of the present invention produce solder joints, which typically withstand forces up to 6,000 psi, well above the recommended values for conventional ICAs.

Standard solders, such as those employed in the composition of the present invention, have resistivities of about 13 .mu..OMEGA.-cm. For ICAs, MIL-STD883c.M5011.2 recommends a maximum acceptable value of 300 .mu..OMEGA.-cm. Thus, the present invention produces joints well within the MIL spec. A major concern with ICAs is the stability of the junction resistance following environmental tests. An increase in resistance of no more than 20% after each environmental or mechanical test is recommended. Since the present invention produces encapsulated solder joints, environmental and mechanical tests are not expected to produce any significant changes in the resistivity of the bond.

There has thus been presented solder paste incorporating a polymer-based flux composition that combines the environmental and processing advantages of ICAs with the joint-forming advantages of solder based materials. The invention has been described with respect to specific examples.