Processing of SMD LEDs
Processing of SMD LEDs
Document
Published by
ams OSRAM Group
www.osram-os.com
Application Note
Valid for:
SMD LEDs from OSRAM Opto Semiconductors
Abstract
This application note provides a basic overview of the essential aspects and influencing
factors regarding the processing of SMD LEDs.
Table of contents
A. Introduction ............................................................................................................ 2
B. SMD LEDs .............................................................................................................. 3
C. Processing of SMD LEDs ...................................................................................... 5
Solder pad design .............................................................................................. 6
PCB pad finishes ............................................................................................... 7
Solder paste printing / solder stencil ................................................................. 8
3D SPI (Solder Paste Inspection) ..................................................................... 10
Reflow soldering .............................................................................................. 11
Voids ................................................................................................................ 13
Solder joint / post reflow inspection ................................................................ 14
Storage ............................................................................................................ 15
Cleaning ........................................................................................................... 15
D. Summary .............................................................................................................. 16
A. Introduction
In general, LEDs do not differ in terms of processing from other electronic SMD
components. However, because of their optical properties their specific package
materials might be more sensitive, and thus the LEDs can be rapidly impaired or
may fail totally with regard to their electro-optical features if they are not correctly
handled or assembled. With progressive miniaturization and new package
concepts, requirements for LED processing are becoming more demanding, for
example in respect to the assembly and soldering processes.
With new miniature high power LEDs it is for example essential that the soldering
process is designed and adapted in the way that defects (voids) in the solder
joints are minimized. The lower the number of voids, especially at the thermal
pad of the LED, the better the thermal connection to the PCB and thus the lower
the thermal load. This in turn influences the performance and lifetime of the LED.
The possible extent of influence is diverse in such cases and is usually not
determined by only a single processing step. Factors such as component finish,
material and composition of the solder, design of the solder stencil, reflow solder
profile or process atmosphere are interlinked and contribute to the solder result.
B. SMD LEDs
SMD (Surface mounted device) LEDs are usually defined as devices with
packages that can be soldered directly onto the surface of a printed circuit board
via solder-capable contacts. Plastic molding compounds, ceramic or epoxy
substrates are used for the package, cast with epoxy or silicone.
According to the package type and variant, the contacts of traditional LED
devices are usually formed as Gull-Wing or J-Leads. With newer types of
package, especially for higher packing densities, the solder joints are small
metal-coated connection surfaces on the backside of the package (bottom only-
terminated (BoT)). Figure 1 shows a selection from the SMD LED portfolio of
OSRAM Opto Semiconductors.
Figure 1: Selection from the SMD LED product portfolio of OSRAM Opto
Semiconductors
OSLON®
Black Flat
OSLON®
r
we Compact PL
h po
Hig
n d:
Tre OSRAM OSTAR®
Advanced OSLON®
Power TOPLED®
Power TOPLED®
As with all products from OSRAM Opto Semiconductors, also its SMD LEDs
fulfill the current RoHS guidelines (European Union & China), and therefore
contains no lead or other defined hazardous substances.
Figure 2: Dry packing of SMD LEDs with Humidity Indicator (HIC) and Barcode Product
Label (BPL)
The BPL also references the ESD-, and moisture sensitivity class, development
designation, brightness class and grouping of the LEDs as supplementary
information if required. It is generally recommended to check the bag after
receipt for damage and completeness. No holes, dents or fissures of any type
should exist that could impair the content. For the storage of its SMD LEDs in
unopened dry packaging, OSRAM Opto Semiconductors specifies a maximum
storage time of 24 months (shelf life) with ambient conditions not exceeding
40 °C and a humidity content of max. 90 % RH (relative humidity). Further
information can be found in the ZVEI guide for the long-term storage of
components, assemblies and devices (“Leitfaden – Langzeitlagerfähigkeit von
Bauelementen, Baugruppen und Geräten”).
It is necessary to check the moisture indicator card contained inside directly after
opening and before processing of the components. The indicator changes color
from blue to pink when the corresponding moisture grade is exceeded. If the
color changes, the specified handling information (see HIC and moisture
sensitive label – ML) must be observed and the components should be dry
backed if necessary (also see JEDEC J-STD-033). After opening the dry bag,
LEDs have a specific floor life depending on their moisture level classification
(according to JEDEC-STD-020). The floor life specifies the time period after
removal from a dry bag, dry storage or dry bake and before reflow soldering.
1 No limit
2 1 year
2a 4 weeks
3 168 hours
4 72 hours
5 48 hours
5a 24 hours
6 6 hours
The information regarding the assigned moisture sensitive level (MSL) can be
found in the corresponding data sheet of the LED or on the Barcode Product
Label.
Note: The MSL makes no fundamental “statement” about the solder capability
(solderability) of the components.
It is generally recommended to leave not required reels in their packaging, and
to store components during processing in ambient conditions of ≤ 10 % RH.
Drying cabinets with dry nitrogen (N2) or dry air are suitable for this type of
storage. With regard to dry packs, further information can be found on the
Internet and in the Short Form Catalog in the “Tape and Reel” chapter, under the
topic “Dry Pack”. Normative references such as JEDEC can also be found here.
SMD LEDs
Cu solder pad
However, it should be noted that the self-centering effect is limited in its extent.
Slightly misaligned components (less than 0.150 mm) are automatically aligned
during reflow due to the self-centering effect of the symmetrical pad design
(Figure 5). If the placement position is offset more than 150 μm from the center,
the components should not be reflowed, as electrical shorts resulting from solder
bridges may occur. Since the placement and rotational alignment of the
component depends also on the process and equipment, optimization must take
both factors into consideration.
Figure 5: Self alignment during reflow soldering (e.g @OSLON, OSRAM OSTAR SMT
and OSRAM OSTAR Compact)
Before reflow During reflow After reflow
Figure 6: Example of a stencil aperture for LEDs of the OSLON product family
2,6 [0,102´´]
0,3 [0,012´´]
2,6 [0,102´´]
0,9 [0,035´´]
0,45 [0,018´´]
0,4 [0,016´´]
solder stencil
The stencil apertures are typically smaller than the recommended solder pad.
Stencil thickness used in the SMT industry varies from 100 μm to 150 μm
(0.004 in to 0.006 in). OSRAM Opto Semiconductors typically recommends
120 μm for SMD LEDs, resulting in a solder-joint thickness (standoff height)
which is typically between 40 μm to 75 μm.
However, the stencil thickness used may also depend on other SMD
components on the PCB. For an ultra-compact high power SMD LED package
such as OSLON® Compact, OSRAM Opto Semiconductors has found in internal
tests that an optimized stencil aperture and thickness may minimize tilting and
result in very good self-alignment. The two stencil aperture designs are shown in
Figure 7. In addition to the design itself, the thickness of the solder paste was
adapted from 120 μm to 100 μm.
Figure 7: Stencil aperture and proper solder paste print for OSLON® Compact CM
Aperture design 1:1 Aperture design 2 pads
120 μm 100 μm
The adapted design and thickness of the solder stencil result in significant
improvements of the alignment and minimized tilting after reflow soldering
(Figure 8).
Figure 8: Comparison of solder result for the different stencil designs and thicknesses
(e.g OSLON® Compact CM)
Higher risk of tilting Less tilting
(aperture design 1:1, 120 μm) (Aperture design 2 pads, 100 μm)
Generally, SMD LEDs from OSRAM Opto Semiconductors are compatible with
existing industrial SMT processing methods, where automated pick & place
equipment provides the best handling and placement accuracy. In the
application note “Recommended pick and place tools for LEDs from OSRAM
Opto Semiconductors” a catalog with a linkage of the tools successfully tested
is shown for the SMD LED product families. When processing by means of
automated placement equipment and based on in-house pick and place
experiments, OSRAM Opto Semiconductors advises customers to take the
following general pick and place guidelines into account:
1. Care should generally be taken that an appropriate pick and place tool is
used and that process parameters conform to package characteristics. As
a starting point, a placement force of 2.0 N is recommended and should be
minimized where possible.
2. The nozzle tip should be clean and free of any particles since this may
interact in particular with the critical and optical relevant area (area over
die/s and wire bond/s) of the LED package during pick & place
3. To ensure zero defect, and in particular with LEDs, damage-free processing
by the pick & place nozzle, it is a good practice to inspect the top surface
of the LED under a microscope during setup and initial production runs.
Reflow soldering
The individual soldering conditions for each LED type according to JEDEC J-
STD-020E can be found in the respective data sheets. In this regard it must also
be stated that JEDEC J-STD-020E does not represent production profiles for the
user but for the component manufacturer for qualification and classification of its
moisture-sensitive semiconductor components.
A standard reflow soldering process with forced convection under standard N2
atmosphere is recommended for mounting the component, in which a typical
lead-free SnAgCu metal alloy is used as solder. Figure 10 shows the temperature
profile for lead-free soldering with the recommended peak temperature of
245 °C. In this context, it is recommended to check the profile on all new PCB
materials and designs. As a good starting point, the recommended temperature
profile provided by the solder paste manufacturer can be used. The maximum
temperature for the profile as specified in the data sheet should not be exceeded
though.
150
50 Ramp Up
3 K/s (max)
25
0
0 50 100 150 200 250 300
t [s]
Voids
For a good thermal connection and a high board level reliability it is
recommended that voids and bubbles should be eliminated in all solder joints. A
total elimination of voids, particularly for larger thermal pads (such as the
OSLON® family or OSRAM OSTAR® Compact) is difficult however. In industry
standards such as IPC-A-610 D or J-STD-001D (which refer only to surface
mount area array components such as BGA, CSP, etc.) the amount of voids
(verified by the x-ray pattern) should be less than 25 %.
Internal studies and simulations at OSRAM Opto Semiconductors have
determined however that for areas of up to 50 % of the thermal pad area the
voids only have a minor effect on the thermal resistance. The limit of acceptable
voiding can vary for each application and depends on the power dissipation and
the total thermal performance of the system, affected by the PCB materials used.
The comprehension of the mechanisms for the creation of voids during reflow
soldering and the complex issues existing with factors of influence and their
interactions are being analyzed in the industry as part of projects such as “AK
Poren (Void)”. These show that the individual factors mutually influence each
other partly through contrary interactions. Thus, for specific solder processes a
complete approach must be utilized (Figure 12).
Based on internal analyses by OSRAM Opto Semiconductors, the following
general information for the minimization of voids can be deduced:
• The paste type (flux) has a major influence on wetting and porosity → Use
of good wetting pastes, “low voiding pastes”
• Surface metalization of PCB: different PCB finish in combination with
different solder paste may improve wetting
• Reflow profile; Parameters → Time above liquidus (TAL) > 80 s
• Solder atmosphere has significant influence, N2 distinctly improves wetting
dynamics → O2 < 500 ppm
Figure 12: Typical factors for affecting solder voiding (relevant factors in red)
Materials Soldering process
Solder alloy
Solder flux Reflow profile
(TAL) Reflow process
chemistry PCB material Peak temp Confection / vampor phase
outgasing Vacuum
PCB surface
finish Reflow atmosphere
Air / N2
Solder voiding
Footprint Placement
geometry force
Stencil aperture Proper printing
Solder pad Solver pad
design (PCB) coverage
Stencil Time between
thickness print - assembly
Figure 13: Solder pad with solder wetting indicator (e.g OSRAM OSTAR® Compact)
Solder wetting indicator
Storage
PCBs or assemblies containing LEDs should not be stacked so that force is
applied to the LEDs, or should not be handled directly at the LED. Generally, all
LED assemblies should be allowed to return to room temperature after soldering,
before subsequent handling, or the next process step.
Cleaning
Isopropyl alcohol can be used for cleaning since this has been approved by
OSRAM Opto Semiconductors as suitable for most types of SMD LEDs.
However, please be aware that for some of the LEDs a wet cleaning process is
not applicable e.g. due to not hermetically sealed packages. Please refer to the
respective data sheets for further information. In general, if cleaning materials are
used, their suitability must be tested beforehand, particularly as to whether or not
damage is associated with the LED and in respect to long term reliability.
Ultrasonic cleaning of LEDs is not recommended. For dry cleaning, in addition to
purified compressed air (e.g. a central supply or spray can), a clean, soft, lint-free
cloth can be used, especially for LEDs with an epoxy encapsulant. Dry cleaning
of LED devices encapsulated with silicone is not recommended. A combination
of dry and wet cleaning may be required, depending on the type and extent of
the contamination. Special LED type-specific notes for cleaning can be found in
the corresponding data sheets and in the application note “Cleaning of LEDs”.
D. Summary
Generally, all SMD LEDs from OSRAM Opto semiconductors are compatible
with existing industrial SMT processing methods, so that current populating
techniques can be used for the mounting process. Basic recommendations
regarding solder pad/stencil design and reflow solder profile can be found in the
corresponding data sheet of the LEDs. Please visit the website of OSRAM Opto
Semiconductor for additional application notes regarding processing, specific
LED-types, thermal management etc.
When developing circuitry, special attention should be given to the position and
orientation of the LED on the circuit board. Depending on the position and
orientation of the LED, the mechanical stress on the LED may vary.
OSRAM Opto Semiconductors supports its customers during their development
and design processes in order to help them to find the best possible solution for
a specific application.
www.ledlightforyou.com
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