Table Of ContentManufacturing Technology in
the Electronics Industry
Manufacturing Technology
in the
Electronics Industry
An introduction
Phillip R. Edwards
Principal Scientific Officer, British Raii Research, Derby, UK.
luni
SPRINGER-SCIENCE+BUSINESS MEDIA, B.V.
First edition 1991
© 1991 Phillip R. Edwards
Originally published by Chapman & Hali 1991
Softcover reprint of the hardcover 1s t edition 1991
Typeset in 1O/12pt Palatino by Columns Design & Production Services Ud.
ISBN 978-0-412-37130-1
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accuracy of the information contained in this book and cannot accept any legal
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A catalogue record for this book is available from the British Library
Library of Congress Cataloging-in-Publication Data
Edwards, Phillip R., 1958-
Manufacturing technology in the electronics industry : an
introduction / Phillip R. Edwards.
p. cm.
Includes bibliographical references and index.
ISBN 978-0-412-37130-1 ISBN 978-94-011-3130-8 (eBook)
DOI 10.1007/978-94-011-3130-8
1. Electronic apparatus and appliances---Design and construction.
2. Electronic industries. 3. Printed circuits---Design and
construction. 1. Title.
TK7836.E39 1991
621.381-dc20 91-2819
CIP
@ Printed on permanent acid-free text paper, manufactured in accordance with the
proposed ANSIINISO Z 39.48-199X and ANSI Z 39.48-1984
Contents
Contents
Preface vii
1 Introduction to the electronics industry 1
1.1 A history of the electronics industry 2
1.2 The electronics market 10
1.3 Electronics manufacturing company structure 13
1.4 Test engineering and quality assurance 18
2 Electronic components 26
2.1 Component interconnection methods 26
2.2 Electronic components 27
2.3 Component packaging 48
2.4 Cabling 61
2.5 Component quality assurance 62
3 Electronic design 64
3.1 Quality and reliability assessment 64
3.2 The product design process 69
3.3 Circuit design 73
3.4 Integrated circuit design 77
3.5 Circuit layout 81
4 Semiconductor device manufacture 91
4.1 Semiconductor materials 92
4.2 Clean room requirements 94
4.3 Silicon wafer manufacture 97
4.4 Photolithography 99
4.5 Layer fabrication processes 102
4.6 Bipolar junction transistor fabrication 110
4.7 Field effect transistor fabrication 116
4.8 Integrated circuit packaging and testing 124
v
vi Contents
5 Printed circuit board manufacture 130
5.1 Printed circuit board types 131
5.2 Printed circuit board substrate materials 133
5.3 Printed circuit board substrate manufacture 134
5.4 Printed circuit board fabrication procedures 136
5.5 Single-sided printed circuit board manufacture 146
5.6 Double-sided printed circuit board manufacture 148
5.7 Multilayer printed circuit board manufacture 153
6 Printed circuit board assembly 159
6.1 Hand assembly 160
6.2 Automatic component insertion 165
6.3 Assembly-related faults 173
6.4 Soldering techniques 176
6.5 Solder joint inspection and common soldering faults 187
6.6 Cleaning 191
6.7 Testing and reworking 192
7 Surface mount component assembly 197
7.1 Advantages of surface mount components 197
7.2 Surface mount component assembly 199
7.3 Adhesive application 200
7.4 Solder paste application 205
7.5 Component onsertion 209
7.6 Soldering techniques 213
7.7 Mixing surface mount with leaded components 220
7.8 Soldering quality 221
7.9 Testing 223
7.10 Reworking 224
8 Alternative technologies 226
8.1 Hybrid technology 227
8.2 Tape automated bonding 232
8.3 Silicon on silicon wafer-scale integration 234
8.4 Application-specific integrated circuits 235
8.5 Flexible circuits 238
References 241
Further reading 242
Index 243
Preface
The sequence of events which led to the writing of this book started at
a seminar on Manufacturing Technology in the Electronics Industry
given by the Institution of Production Engineers in 1987. The seminar
identified that the field of manufacturing engineering for the electronics
industry was effectively missing from the vast majority of production
engineering degree courses. The reason for this was that production
engineering departments typically spring from mechanical engineering
departments. This leads to a mechanical bias in the practical aspects of
such courses.
The consequence of this was that electronics companies could not
recruit graduates with both relevant production engineering and
electronic engineering backgrounds. This necessitated either recruiting
production engineering graduates and giving them the necessary
electronic engineering training, or giving production engineering
training to electronic engineering graduates. A consequence of the lack
of courses in a subject is that there is also a lack of relevant textbooks
in the area, as most textbooks are intended to tie into courses. In the
field of manufacturing technology for the electronics industry, existing
textbooks tend to be highly specialized and mainly concerned with the
fabrication of semiconductor devices.
The book assumes no previous knowledge of electronics and keeps
the actual electronic theory to a minimum. Where electronic com
ponents are introduced, the emphasis is placed on their handling and
packaging. The main subject areas addressed by this book are
components, design, semiconductor device fabrication, printed circuit
board manufacture, surface mount components, and non-standard
devices and their associated technologies. Each area is viewed with
respect to its impact on the manufacture of electronic devices.
One of the major problems associated with any textbook which
addresses the field of electronics is that technology is continually
advancing at such a rapid pace that sections can rapidly become
obsolete. The manufacturing aspect of the electronics industry is not in
viii Preface
practice changing as rapidly as the component technology. Many
processes can accommodate changes in technology by operating on a
smaller scale. The principles are the same except that process control
needs to be much better. Processing faults which were tolerable on a
larger scale can become unacceptable on a smaller scale.
Modern society has an increasing requirement for cheap, reliable and
increasingly complex electronic devices. This makes the efficient
application of manufacturing technology to the electronics industry an
important and challenging subject area which will be in great demand
for the foreseeable future.
Dr Phillip R. Edwards
1
Introduction to the
electronics industry
The electronics industry encompasses a wide range of different
manufacturing processes and products. The most visible products of
the electronics industry are consumer goods such as television sets,
music reproduction systems and computers. These visible products
represent a tip of the iceberg situation as a large part of the electronics
industry is concerned with the manufacture of the component parts of
products. The manufacture of switches, printed circuit boards,
semiconductor devices and the assembly of complex computer systems
are all aspects of the electronics industry. The fact that each of these
activities would typically be performed by different organizations
shows that there are few common factors across the electronics
industry's component companies.
An electronic product (excluding its packaging or casing), whether it
be a simple transistor radio or a complex supercomputer, consists of
two basic parts - the electronic components (transistors, resistors etc.)
and the interconnections between the components. The electronics
manufacturing industry is primarily concerned with interconnection
technology - the methods of electrically joining the inputs and outputs
of electronic components to form working circuits. Even the companies
which manufacture the actual electronic components have to provide
methods of connecting them to other devices.
This book is primarily concerned with the manufacturing aspects of
the electronics industry. In general a knowledge of the theory of
electronics is not necessary for many manufacturing processes used for
the manufacture of electronic products. The only exceptions to this are
when a device's performance is sensitive to manufacturing-related
parameters.
This chapter is concerned with the global aspects of the electronics
industry. A historical perspective is used to show the impact of rapidly
2 Introduction to the electronics industry
changing technological progress on the industry. The increasing
demands imposed by the market for electronic products is examined
with respect to its effect on the electronics manufacturing industry. In
order to appreciate the differing requirements and the resulting
compromises which need to be reached for a typical product, the
departmental structure and the interaction between departments are
discussed for a typical manufacturing company. The functions of
quality assurance and test engineering are so intimately entwined with
almost every other function that they cannot be considered in isolation.
An overview of the quality and test functions, and their interactions
with other activities, is given. The actual quality and test activities are
described alongside the descriptions of the individual manufacturing
processes where appropriate.
Chapter 2 is concerned with the individual electronic components.
Components are grouped into families with related electrical or
physical characteristics where appropriate. From the manufacturing
point of view, the most important aspects of electronic components are
those of their physical dimensions, their terminal connections, and
their quality.
Chapter 3 is concerned with the design processes, in particular the
design of electronic circuits and the layout of circuits using computer
aided design where appropriate.
Chapter 4 describes the fabrication of semiconductor devices.
Processing from design through to manufacture is covered completely.
Chapters 5, 6 and 7 are concerned with the manufacture of complete
printed circuit boards. Chapter 5 is concerned with the manufacture of
the bare printed circuit board. Chapter 6 is primarily concerned with
the assembly of conventional leaded components into printed circuit
boards. Chapter 7 discusses the introduction of surface-mounted
components and their impact on printed circuit board manufacture.
Chapter 8 completes the discussion by describing some of the non
standard electronic devices and interconnection methods.
1.1 A HISTORY OF THE ELECTRONICS INDUSTRY
The electronics industry has evolved very rapidly since its beginnings.
The enormous advances in technology, particularly since the late
1950s, have imposed considerable pressures towards change. In fact
the progress of change is itself increasing, which makes obsolescence a
serious problem.
A good perspective of this rapid evolution, and how it has
