2004 Volume 45 Issue 3 Pages 793-798
Electrically conductive adhesives (ECAs) have been developed as an alternative to traditional Sn-Pb solders for electronic and optoelectronic applications. However, there are critical limitations such as the low conductivity, and unstable contact resistance. These limitations have seriously hindered the broad applications of ECAs. In order to overcome these limitations, a new formulation using Pb-free conducting filler particles was proposed. Our previous study proved that the metallurgical interconnections among conducting filler particles and between particles an the conducting pads were established by process control. In particular, it was found that the wetting behavior of conducting fillers in ECAs is one of the main mechanisms for the establishment of conduction paths. In this study, we propose the fundamental concept of an assembly process using fusible Pb-free conducting filler particles. Also, the effect of the reduction capability of base resin material on the solder wetting property was investigated. As candidates for ECA compositions, two types of resin materials and two lead-free solders were investigated. The reflow temperature profiles for each ECA formulation were determined using a differential scanning calorimeter (DSC) dynamic scan. The wettabilities of the lead-free solders were investigated using an optical microscope with a CCD camera and a microfocus X-ray television system. It was found that the developed resin material with an intrinsic reduction capability shows good wettabilities in both lead-free candidates.