クリームはんだ印刷機

クリームはんだ印刷機とは

クリームはんだ印刷機とは、プリント基板の上に電子部品を実装する前の工程において、部品を表面実装するために基板上の必要な箇所にはんだを塗布する装置です。

この際に使用するペースト状のはんだのことをクリームはんだと言います。最近ではクリームはんだ印刷機の英語名をそのまま発音して、ソルダーペースト・プリンター (英: solder paste printer) と言うことも増えています。

クリームはんだ印刷機の使用用途

パーソナルコンピューターやスマートフォンを始めとした多くの電子・電気機器は、プリント基板上に演算装置、コンデンサ、抵抗やメモリなど主要な電子部品を集中して取り付けています。そして、それらの部品間では基板表面にプリントされた配線を通じて電気信号の受け渡しを行っています。

プリント基板上に取り付けられた部品間で正しく電気信号のやり取りをするためには、各部品を定められた位置に正確に取り付ける必要があります。基板上に部品を取り付けることを実装と言い、実装には主に二つの方式が存在します。

1. スルーホール実装または挿入実装

基板の表面に部品のリードを通すための穴をあけ、基板の裏側でリードをはんだ付けしてプリント配線で結ぶ方法をスルーホール実装 (英: hrough-hole technology: THT) または挿入実装 (英: Insertion mount technology: IMT) といいます。

2. 表面実装

プリント基板上でプリント配線がある面の、部品のリードを取り付ける箇所にはんだを塗布し、各々のリードが正しく配線に接合されるように部品を置く方法を表面実装 (英: Surface mount technology: SMT)と言います。

電子・電気機器の小型化と高性能化が進むにつれて、電子部品も小型化、高集積化が進み、プリント基板も小型化し、プリント配線も稠密になって来ました。このような状況下では、THTよりもSMTが使われることが多くなります。 クリームはんだ印刷機はSMTにおいて、はんだを正確に塗布する工程を担っており、SMTの歩留まりを左右する重要な装置です。

クリームはんだ印刷機の原理

SMTにおいて、はんだをプリント基板に塗布する際は厚さが数百ミクロンの薄い金属の板でできたマスクを使用します。マスクには、あらかじめはんだを塗布する各箇所にはんだを塗布する形に切り抜いた穴が開いています。

このマスクは材質が金属であることからメタルマスクと言われたり、穴を切り抜いてパターンを作っていることからステンシルマスクとも言われます。このマスクをプリント基板に密着させ、マスクの上からはんだを流しながらスキージ (英: squeegee) を使ってはんだを穴から流し込みます。

マスクがプリント基板に正確に重ねられていないと、はんだの位置がずれるため、マスクとプリント基板の位置関係が非常に重要です。プリント基板にはんだを塗布する作業は、マスクとスキージがあれば一枚ずつ手作業でも可能ですが、工業的に何枚ものプリント基板にはんだを塗布する場合にクリームはんだ印刷機を使用します。

クリームはんだ印刷機は、プリント基板にマスクを正確に重ね合わせ、ヘッダーという部品からはんだをマスクの上に流し、スキージでマスクの穴からプリント基板上にはんだを流し込みます。はんだの塗布が終わったプリント基板はマスクを分離し、印刷検査機で検査された後マウンター工程に送られます。マウンター工程で部品が搭載されるとプリント基板がリフロー工程に送られ、熱を加えられてはんだが溶融して冷えて固まることで部品のプリント基板への装着が完了します。

SMTでは、部品のリードがプリント基板を貫通して反対側の面に出ることがないので、両方の面に部品を装着する両面実装も多く行われています。

クリームはんだ印刷機の選び方

クリームはんだ印刷機を選ぶ際には、適応可能なプリント基板のサイズを確認した上で、歩留まりとスループット、ランニングコストなどを考慮します。

歩留まりに大きく影響するのは、プリント基板へのマスクの重ね合わせ精度と、プリント基板とマスクの密着性です。重ね合わせ精度が良くないとはんだの位置がずれやすく、プリント基板の不良が発生しやすくなります。プリント基板に対するマスクの密着が良くないと、はんだが定められた場所の周囲にまで広がって塗布されてしまい、歩留まり低下の原因になります。

スループットを考慮する際には装置のはんだの塗布にかかる時間だけではなく、工程の組み換えやクリーニングのために装置の稼働を停止している時間も重要な要素として検討する必要があります。一方、スループットを高める方法として、一台で2枚のプリント基板に対して並行してはんだの塗布を行える装置もあります。ランニングコストを考える際にははんだを無駄なく使え、基板への塗布が終了してマスクの上に残ったはんだを回収して再利用できるかどうかも検討の対象になります。

注目のクリームはんだ印刷機

PR プレミアム印刷機 YSP10

クリームはんだ印刷機

ヤマハ発動機株式会社

高速・高品質印刷と段取り替えの全自動化対応

詳細をみる

YSP10は、段取り替えの全自動化に対応し、サイクルタイム12秒(クリーニング込・当社
最適条件)の高速印刷を実現したクリームはんだ印刷機です。

自動プログラム切り替えやPSC(Print Stability Control)システムによる印刷安定制御といった機能に加え、「バックアップピン自動交換」「マスク自動交換」「ハンダ自動移載」(いずれもオプション)を追加搭載することで、段取り替え作業の全自動化を実現できます。

公式サイトはこちら

クリームはんだ印刷機

印刷品質を安定させる多彩な機能

■ヤマハ独自の3Sヘッド
スキージのアタック角度と速度をプログラムにより任意に設定・変更でき、使用するハンダに応じた最適条件で印刷が可能。

■マスク吸着
マスク吸着機能によりマスクのたわみに影響されない安定した高精度印刷が可能。往復印刷時のオフセット入力を不要にし、段取り時間を大幅に短縮。

■自動クリーニングシステム
高効率クリーニングシステムを標準装備。新クリーナーヘッドによりクリーニング不織布の消費量を大幅に削減。

■グラフィック目合わせ機能
2つのカメラ画像をレイヤー合成することで、基板と印刷マスクの相対位置あわせを簡単・精密に操作可能。

ヤマハ検査装置ラインナップはこちら

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Potassium Sulfate

What Is Potassium Sulfate?

Potassium sulfate (K2SO4), also known as arcanite, is an inorganic compound widely used in the agricultural sector as a chemical fertilizer. It provides essential nutrients, particularly potassium and sulfur, to various crops, especially fruit-bearing plants, enhancing fruit quality and size. This compound also finds applications in pharmaceuticals, glass manufacturing, and as a component in certain chemical reactions.

Uses of Potassium Sulfate

Its primary role is in fertilizer production due to its solubility and nutrient content. Potassium sulfate is also used in dyeing processes, as a raw material for other potassium compounds, and historically, as a medicinal substance.

Properties of Potassium Sulfate

As a colorless, water-soluble crystal, potassium sulfate has a high melting point and does not form hydrates. Its solutions are clear, hard, and have a bitter taste, making it distinct from other sulfate salts.

Structure of Potassium Sulfate

It exhibits an orthorhombic crystal structure at room temperature, transitioning to an alpha form at temperatures above 583°C. The sulfate ions within form a tetrahedral arrangement, contributing to its chemical stability.

Other Information on Potassium Sulfate

1. Historical Background

Known since the early 14th century, potassium sulfate has been explored by notable chemists over the centuries for its properties and applications.

2. Natural Occurrence

Found naturally in mineral deposits, it often coexists with magnesium, calcium, and sodium sulfates. Minerals like kainite, picromerite, and langbeinite are common natural sources.

3. Synthesis Methods

Industrially, it is produced by reacting sulfuric acid with potassium chloride or through the double decomposition of magnesium sulfate and potassium chloride.

4. Chemical Reactions

When combined with sulfuric acid, potassium sulfate forms potassium hydrogen sulfate, demonstrating its reactive nature and versatility in various chemical processes.

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Aluminum Sulfate

What Is Aluminum Sulfate?

Aluminum sulfate, known as alum or alumite, is a vital chemical compound with the formula Al2(SO4)3. It exists in several hydrated forms, with 14-18 hydrates being the most common. Due to its acidic and astringent properties, it’s widely used across various industries, albeit classified as a deleterious substance due to its potential toxicity.

Uses of Aluminum Sulfate

Primarily used as a coagulant in water treatment processes, aluminum sulfate also finds application in dyeing, soil conditioning, pharmaceuticals, pigments, and as a fire extinguishing agent. In the paper industry, it’s employed as a sizing agent to improve paper quality.

Properties of Aluminum Sulfate

This compound is known for its solubility in water, forming acidic solutions that can precipitate aluminum hydroxide when neutralized. It’s stable in the air but undergoes thermal decomposition at high temperatures, yielding alumina and sulfur oxides.

Structure of Aluminum Sulfate

Anhydrous aluminum sulfate is a colorless crystal, while its hydrates form needle-like structures. The compound’s ability to form complex salts is leveraged in producing other aluminum salts.

Other Information on Aluminum Sulfate

1. Synthesis of Aluminum Sulfate

Produced industrially by treating bauxite or clay with sulfuric acid, aluminum sulfate is purified to remove iron ions, yielding a high-purity product. It can be dehydrated to an anhydrous form by heating.

2. Impact on Acidic Paper

Aluminum sulfate’s use in paper manufacturing leads to increased acidity, potentially causing the paper to deteriorate over time. This has implications for the long-term storage of documents and books.

3. Related Compounds

Related to aluminum sulfate is potassium alum, a compound salt used in various applications, formed by reacting aluminum sulfate with potassium sulfate in aqueous solution.

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Sulfuric Acid

What Is Sulfuric Acid?

Sulfuric acid (H2SO4), a colorless and odorless acidic liquid, is a fundamental raw material in the chemical industry, known for its versatility in various fields such as fertilizer production, metal smelting, and battery manufacturing. Classified for its potential to cause severe chemical burns, sulfuric acid demands careful handling.

Uses of Sulfuric Acid

Its applications span across creating fertilizers, dyes, and explosives, and refining oil and fats. Sulfuric acid acts as a key reagent in chemical synthesis, serving as a dehydrating, oxidizing, and drying agent. It’s also crucial in producing lead-acid batteries for cars.

Properties of Sulfuric Acid

This highly corrosive acid has a significant density and exhibits strong acidity, capable of reacting with metals and organic compounds through various mechanisms, including dehydration and sulfonation. Its high heat of dissolution necessitates careful dilution practices to avoid hazardous reactions.

Types of Sulfuric Acid

Sulfuric acid is categorized based on concentration: dilute (less than 90%) and concentrated (more than 90%). Special forms include hot concentrated sulfuric acid and fuming sulfuric acid, each with unique properties and industrial applications.

Sulfuric Acid Production

Modern industrial production predominantly uses the contact method, where sulfur dioxide is oxidized to sulfur trioxide and subsequently absorbed in water to form sulfuric acid. This method is preferred for its efficiency and purity of the final product.

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Copper Sulfide

What Is Copper Sulfide?

Copper sulfide encompasses a family of chemical compounds formed from copper and sulfur, with notable examples being copper(I) sulfide (Cu2S) and copper(II) sulfide (CuS). These compounds occur naturally in various mineral forms and are recognized for their potential toxicity, requiring careful handling under safety regulations.

Uses of Copper Sulfide

Utilized across various industries, copper sulfides serve as raw materials for metallic copper, catalysts, pigments, ship-bottom paints, and textile dyeing. Their application extends to the manufacture of fluorescent paints, sulfur and copper products, antistatic fibers, and as developers in photography for sepia tones.

Properties of Copper Sulfide

Characterized by their electrical conductivity and insolubility in water, copper sulfides differ in their solubility with respect to acids and ammonia water. They are known for transitioning between different crystalline forms depending on the temperature, showcasing unique properties suitable for specific industrial applications.

Structure of Copper Sulfide

Copper sulfides exhibit varied crystal structures. Copper(I) sulfide exists in alpha and beta forms, with specific densities and melting points. Copper(II) sulfide presents a hexagonal structure that becomes monoclinic at elevated temperatures, illustrating the complex coordination between copper and sulfur atoms.

Types of Copper Sulfide

Beyond Cu2S and CuS, the copper sulfide family includes minerals like yarrowite (Cu9S8), spionkopite (Cu39S28), and others, each with distinct compositions and properties.

Other Information on Copper Sulfide

1. Synthesis of Copper Sulfide

Copper(I) sulfide can be synthesized by heating copper with excess sulfur or by roasting brass ores, with further processing in oxygen to isolate metallic copper.

2. Reaction of Copper Sulfide

Copper sulfides react with nitric and sulfuric acids to form various compounds, including copper(II) nitrate and sulfate. The presence of copper(II) ions can be detected analytically by the formation of a black precipitate of copper(II) sulfide when reacted with hydrogen sulfide.

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Iron Sulfide

What Is Iron Sulfide?

Iron sulfide represents a group of compounds formed from iron and sulfur, including various forms such as ferrous iron sulfide (FeS), ferric iron sulfide (Fe2S3), and ferrous iron disulfide (FeS2, commonly known as pyrite). These compounds are recognized for their varied applications and are subject to safety regulations due to their hazardous properties.

Uses of Iron Sulfide

Iron sulfide is utilized in various industries for manufacturing sulfuric acid, alloys, and stainless steels, and as a decomposition agent in steel casting. It’s also employed in agricultural applications, wastewater treatment, and as a reducing agent in refining crude phosphoric acid.

Properties of Iron Sulfide

These compounds exhibit distinct physical properties, including solubility in dilute acid and high melting points. Ferrous iron sulfide (FeS) is known for producing hydrogen sulfide when dissolved in acid, while iron disulfide (FeS2) serves as a raw material for sulfuric acid.

Types of Iron Sulfide

The iron sulfide family includes minerals like pyrite (FeS2), marcasite (also FeS2 but with a different crystal structure), troilite (FeS) found in meteorites, pyrrhotite (Fe1-xS) with variable iron-to-sulfur ratios, greigite (Fe3S4), and mackinawite ((Fe, Ni)1+xS).

Other Information on Iron Sulfide

Sulfide Minerals Other Than Iron Sulfide

In addition to iron sulfide, other sulfide minerals include copper, lead, zinc, nickel, mercury, molybdenum, cobalt, and antimony. Typical sulfide minerals are pyrite CuFeS2, pyrite FeS2, galenaite PbS, and sphalerite ZnS. The metals that form sulfide minerals combine with arsenic, tellurium, and selenium instead of sulfur to form arsenide, telluride, and selenide minerals.

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Hydrogen Sulfide

What Is Hydrogen Sulfide?

Hydrogen sulfide (H2S) is a colorless gas known for its distinct rotten egg odor, acting as a hallmark of sulfur and hydrogen combination. Despite its malodorous nature, it plays a significant role in various industries and natural processes.

Uses of Hydrogen Sulfide

It serves as a crucial raw material in the manufacture of sulfur-containing chemicals, heavy metal salt analysis, and organic synthesis. Hydrogen sulfide also finds applications in separating heavy water for nuclear magnetic resonance analysis.

Properties of Hydrogen Sulfide

With a molecular weight of 34.082 and a specific gravity of 1.1905 relative to air, hydrogen sulfide is flammable and combustible. It dissolves in water to form a slightly acidic solution and decomposes at around 400°C. Naturally occurring in volcanic gases and hot springs, and as a byproduct of organic decay, hydrogen sulfide poses significant hazards at high concentrations.

Other Information on Hydrogen Sulfide

1. Production of Hydrogen Sulfide

Industrial production comes from natural gas and petroleum refineries, with processes involving the reaction of sulfur with methane at high temperatures, absorption from flue gases, and as a byproduct of carbon disulfide production. Pure hydrogen sulfide can also be synthesized by reacting sulfur with hydrogen.

2. Hazards of Hydrogen Sulfide

Highly toxic, hydrogen sulfide can cause severe health issues, including damage to the nervous and respiratory systems. Its flammability and combustibility make it a significant risk in both industrial and environmental settings. Awareness of its dangers is crucial for safe handling and exposure prevention.

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Sodium Sulfide

What Is Sodium Sulfide?

Sodium sulfide (Na2S) is an inorganic compound, typically found as a hexahydrate. It forms strongly alkaline solutions due to hydrolysis and reacts with acids to produce hydrogen sulfide, necessitating careful handling.

Uses of Sodium Sulfide

Its applications span pharmaceuticals, food additives, lubricants for viscose human silk, leather dehairing, dyeing aids, PPS resin production, copper flotation, wastewater treatment, glass, and pulp production. It’s also used in small-scale experiments, semiconductor manufacturing, and in common products like desiccants and bath salts.

Properties of Sodium Sulfide

Deliquescent and highly water-soluble, sodium sulfide dissolves with exothermic reactions. It’s soluble in alcohol but insoluble in ether. Its anhydrous form melts at 950°C, while the hexahydrate and pentahydrate have lower melting points and decompose at high temperatures.

Structure of Sodium Sulfide

The anhydrous form has a cubic structure, with sodium ions occupying positions analogous to fluoride ions in calcium fluoride. The hydrates form colorless tetragonal crystals, with varying densities across different hydrate forms.

Other Information on Sodium Sulfide

1. Synthesis of Sodium Sulfide

Produced by reacting sodium hydroxide with hydrogen sulfide, heating hydrates in hydrogen, or direct reaction of sulfur with sodium. Industrially, it’s made by reducing sodium sulfate with coke.

2. Reaction of Sodium Sulfide

Reacts with air’s carbon dioxide and oxygen to form various sodium salts, and oxidizes to produce sodium sulfate. In aqueous solutions, it can dissolve sulfur to form polysulfides.

3. Characteristics of Sodium Tetrasulfide

Na2S4 is a yellow crystal soluble in water and ethanol, used in analytical reagents, desulfurizing agents, and more. It liberates sulfur when exposed to air and is corrosive and toxic.

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Calcium Sulfide

What Is Calcium Sulfide?

Calcium sulfide (CaS) is a colorless solid at room temperature, with a CAS number of 20548-54-3. It is known for its low solubility in cold water and its applications across various industries.

Uses of Calcium Sulfide

Calcium sulfide is utilized in lubricating oils, electronic emitters, paints, varnishes, food preservatives, leather tanning, landfill materials, recycling of plaster casts, coal product treatment, electroluminescent materials, and agricultural insecticides and fungicides.

Properties of Calcium Sulfide

It has a molecular weight of 72.14, a high melting point of 2,525°C, and a density of 2.8 g/mL. The compound is almost insoluble in cold water, with a solubility of 0.015g/100mL at 10°C.

Structure of Calcium Sulfide

Its crystal structure forms a cubic lattice, with sulfur atoms surrounded by six calcium atoms in an octahedral arrangement, and vice versa.

Types of Calcium Sulfide

Primarily available for research and development, calcium sulfide is sold in quantities suitable for laboratory use and stored at room temperature.

Other Information on Calcium Sulfide

1. Synthesis of Calcium Sulfide

It can be synthesized by heating calcium sulfate with carbon under oxygen-free conditions, or by passing hydrogen sulfide through heated calcium oxide.

2. Chemical Reaction of Calcium Sulfide

It reacts with moisture to produce calcium hydrosulfide and hydroxide, and with dilute acids to release hydrogen sulfide. Oxidation in dry air yields calcium thiosulfate.

3. Toxicity of Calcium Sulfide

Calcium sulfide is harmful, causing skin and eye irritation, and potentially irritating the respiratory tract. It is classified for skin and eye irritation under GHS criteria and is toxic to aquatic life.

4. Precautions for Storage of Calcium Sulfide

Store in closed containers away from heat, humidity, oxidizing agents, and acids to prevent the production of toxic gases such as hydrogen sulfide.

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Silver Nitrate

What Is Silver Nitrate?

Silver nitrate is a chemical compound with the formula AgNO3, known for its deleterious properties. It must be stored away from light in a tightly closed container. Classified under various safety regulations, silver nitrate is recognized for its potential hazards and is handled with care in environmental and chemical management.

Applications of Silver Nitrate

1. Photographic Industry

Used as a primary material for manufacturing photosensitive silver bromide.

2. Pharmaceuticals

Applied as an antiseptic, astringent, and in eye drops for newborns and treatments for stomatitis and tooth sensitivity.

3. Chemical Field

Employed as an analytical reagent for detecting chloride ions, besides its use in silver plating, mirror production, disinfectants, catalysts, hair dyes, ceramics coloring, ink production, and electrical contacts.

Properties of Silver Nitrate

With a density of 4.352 g/cm3 and a melting point of 212°C, silver nitrate forms colorless orthorhombic crystals. It’s a strong electrolyte, highly soluble in water and slightly in acetone and methanol, but not in benzene. Silver nitrate reacts with organic matter, leading to black silver deposits. It decomposes at 444°C, yielding metallic silver and nitrogen oxides.

Other Information on Silver Nitrate

1. Synthesis of Silver Nitrate

Produced by dissolving silver in nitric acid, yielding nitrogen dioxide or nitrogen monoxide depending on the acid concentration. This method is widely used for industrial production.

2. Silver Mirror Reaction

Occurs when ammoniacal silver nitrate solution is reduced, depositing silver on glass surfaces. This plating technique is utilized for creating silver mirrors.

3. Cautions for Using Silver Nitrate

Reacts with ammonia to form explosive fulminating silver, necessitating careful disposal with hydrochloric acid or sodium chloride solution to prevent accidents. The theft of large quantities has prompted serious security concerns due to its potential misuse.