Hyperclean PX3800 presentation 2017
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The document discusses the performance and advantages of Hyperclean® stencil wiper rolls, emphasizing that a significant percentage of board defects originate during the printing process. It highlights the essential features of the cleaning fabric, such as reduced lint, better cleaning efficiency, and recyclability, while comparing various fabric types. Moreover, it presents cost-effective outcomes, showing a notable reduction in repair rates and overall cleaning costs using Hyperclean® products.
Hyperclean PX3800 presentation 2017
- 1. SMT Stencil Wiper Rolls Performance for a competitive edge HYPERCLEAN®
- 2. Background • 70% of board defects detected at end of the line have their origins at the printing stage. • The under stencil cleaning process is critical • One of the key materials in this process is the cleaning fabric 6/9/2017 Copyright SMT Express 2
- 3. Six design targets 1. No lint from fabric or core 2. Better cleaning by advanced fiber structure 3. ESD safe 4. Reduced solvent consumption 5. Reduced roll change over time 6. Recycable without separation of parts 6/9/2017 Copyright SMT Express 3
- 4. Fabrics on the market Cellulose/Polyester Paper mainly from China Cellulose/Polyester hydro-entangled non-woven Rayon (viscose)/Polyester Paper/Fabric Polypropylene 6/9/2017 Copyright SMT Express 4
- 5. Lint from Cellulose fabric 6/9/2017 Copyright SMT Express 5
- 6. Hyperclean PX3800 close up 6/9/2017 Copyright SMT Express 6
- 7. Important facts • Rayon/cellulose based fabrics have lose fibres, always! • Reducing lint in such fibres results in decreased cleaning performance • Thermal point bond PP is the only viable non-linting alternative! • PP manufacturing and formulation is more complicated • Not possible to take PP for diapers and sell as stencil rolls. 6/9/2017 Copyright SMT Express 7
- 8. Polypropylene core Paper core PX3800 precision core 6/9/2017 Copyright SMT Express 8
- 9. Cleaning test 1 6/9/2017 Copyright SMT Express 9 Rayon/Polyester 30% left Hyperclean PX3800 8% left Cellulose/Polyester - 25 %
- 10. Cleaning test 2 6/9/2017 Copyright SMT Express 10
- 11. Vaccuum cleaning results Rayon Polyester HYPERCLEAN Cellulose Polyester 6/9/2017 Copyright SMT Express 11
- 12. ESD protection 1. Antistatic finishing of fabric 2. Dissipative core 3. ESD controlled manufacturing 4. Dissipative plastic bag 6/9/2017 Copyright SMT Express 12
- 13. ESD check 6/9/2017 Copyright SMT Express 13
- 14. Cleaning liquid absorption Cellulose fibres Hyperclean
- 15. Easy handling •As many meters on the roll as possible •12 m instead of 10 or 11, for example •Smart adhesive, no liner to peel of 6/9/2017 Copyright SMT Express 15
- 16. Fabric fixation • Dots or strips of adhesive • Fabric breaking up • Peel off liner • Advanced adhesive • Full length • No liner • No fabric break up 6/9/2017 Copyright SMT Express 16
- 17. Recycable as one unit Core Fabric material Re-cycable as 1 unit Fabric re-cycable Core re-cycable PVC Polyester + Cellulose/Rayon NO NO YES Paper PP NO YES YES Paper Rayon NO Maybe YES Plastic Rayon NO Maybe YES PP PP YES YES YES 6/9/2017 Copyright SMT Express 17
- 18. Cost for stencil cleaning, example from user Standard roll • 5 boards per cleaning cycle • Roll length 11 m • 3500 ppm AOI error rate Hyperclean • 7 boards per cleaning cycle • Roll length 12 m • 1500 ppm AOI error rate = 60% reduction of repairs! 6/9/2017 Copyright SMT Express 18 Total cleaning process cost reduced by 50%!
- 19. Simply the best! HYPERCLEAN® www.smt-express.com 6/9/2017 Copyright SMT Express 19 Hyperclean name and logo are registred trade marks!
Editor's Notes
- #2: The EMS industry faces many challenges in stencil cleaning due to the rapid expansion of fine pitch applications. This has highlighted the need for high performance, reliable stencil wiper rolls. This presentation will show you why Hyperclean Stencil Wiper Rolls are the best solution from not only the performance view point but also the very low Environmental Impact position.
- #3: Solder paste screen printing is known to be one of the most difficult processes to quality assure in Printed Board Assembly (PBA) manufacturing. The performance of the print process has a critical effect on end-of-line yield. It is known that around 70% of board defects detected at end of the line have their origins at the printing stage. An important process step in solder paste screen printing is the under stencil cleaning process and one of the key materials in this process is the stencil cleaning wiper fabric. This, often neglected, material affects the cleaning process and thereby also the print quality. During solder paste printing, the stencil needs to be cleaned at certain intervals depending on the size, shape, pitch and wall evenness of the stencil apertures, as well as the characteristics of the solder paste. The status and type of screen printer cleaning unit are also significant for the choice of cleaning interval as is the cleaning agent, cleaning roll design and the cleaning process parameter settings. Under stencil cleaning fabric adsorb flux and trap solder particles during the cleaning cycle. It is important that a cleaning fabric is lint-free, has enough distances between fibres for vacuum cleaning and that solder particles are trapped and not released during the cleaning cycle. The cleaning agent shall wet out on a controlled area during the wetting of the cleaning paper and the cleaning paper shall not change its mechanical properties much when being wetted. It is also generally regarded as preferable if the cleaning agent stays on the fibre surfaces instead of being absorbed by the fibres. This makes it easier to transfer the cleaning agent to the stencil in order to dissolve the solder paste flux.
- #5: Most products on the market are a non woven cellulose/polyester. This type a fabric is well known for industrial cleaning and mopping up liquids. The cellulose part absorbs liquid while polyester fibres act as fabric reinforcement. Without the polyester, the fabric would become “mushy” when wet. Most manufacturers of stencil rolls use paper available on the market, but it´s rarely developed for SMT stencil cleaning.
- #6: Pictures shows lint from a cellulose based fabric. The fibres will eventually find their way to the PCB and into a solder joint or under a small component.
- #7: 100% polypropylene fibers dry laid non-woven with random orientation and the thermal bonding operation makes the surface ‘wavy’ and so better cleaning performance than smooth surface products. The fabric traps the solder paste within the fibers unlike very smooth surface combination paper products where the solder paste stays on the surface creating solder flakes & potential contamination as the solder paste dries out. Non Linting so it will not block the stencil apertures. Hyperclean fabric will not swell or become weak as a result of liquid absorption. The physical properties are the same wet or dry unlike cellulose based products. Non-abrasive, giving longer stencil life.
- #9: A paper core, even if made from Kraft paper, can emitt particles. Our 100% PP core is precision made and will not release any minute particles. The core is ESD safe by PP’s natuarl low tribocharging and by additative chemsitry. The core is specal made for SMT Express and Hyperclean in a high end production line. Diameter, roundness and length have tight tolerances. PVC cores, used mainly in Asia, should be avoided as PVC is a ”dirty” material and not ESD safe.
- #10: A small pattern of solder paste was printed on a stencil. After one single dry cleaning cycle, the weight reductions was measured. Hyperclean PX3800 typically adsorbs 20-40% more solder paste. Results are the same in a real printer as in lab tests in test jigs.
- #11: Completely filled apertures….
- #12: Result after a standard cleaning cycle W/V/D The unique properties of the fibers together with our advanced processing technology produces a fabric with optimum vacuum performance. The vacuum performance of cellulose/rayon/polyester is not as good and normally not even specified by the manufacturers. Please note the smearing of solder paste on the stencil surface! (Blue arrows) The Rayon Polyester is Sontara Cleanmaster! This material was also showing bad results in the IPC report.
- #15: Cellulose based products can absorb moisture even before insertion into the printer. When the solvent is applied it is firstly absorbed into the body of the fibers. This can result in swelling of the fibers. When wet the physical properties are completely transformed into a ‘mushy’ texture. The special properties of Hyperclean fibers keeps the solvent on the outside of the fabric and rapidly spreads over the whole area, making the cleaning process more efficient, with the potential to use less IPA resulting in cost savings and reduction of IPA vapor in the environment. The special properties of Hyperclean totally eliminate any swelling of the fibers thereby preventing any jamming of the fabric in the machine.
- #16: Every second counts! With Hyperclean you spend less time on roll change.
- #17: An advance glue is used to fix the fabric to the core. This glue can be used again when an empty core is used as take up spool. No need to peel of liner Faster change over Full with adhesive prevents jamming
- #18: Hyperclean fabric + the core used for pick up of the used fabric is 99% polypropylene and 100% plastic. It can (and should be recycled) as one unit. No need to unwind the fabric and separate core.
- #19: This is an examnple from a customer. The ”cheap” roll they used had a low price per roll. With Hyperclean, they could print more boards, reduce line stop for roll changes and reduce solder defect by 60%! Always analyze the total cost for your SMT stencil cleaning process! The price per roll must not be the focus. There is always a cheaper roll, if you prepared to take the cost!