The Sonochemistry Centre - Loughborough University...Sonochemistry Centre at Coventry University...
Transcript of The Sonochemistry Centre - Loughborough University...Sonochemistry Centre at Coventry University...
An Evaluation of Sonochemical Surface Modification for Electronic Manufacture
Dr Andy Cobley
Prof. Tim Mason
The Sonochemistry Centre
SUMEEPnet Workshop(Sustainable Use of Materials for
Electronic & Electrical Products network)
Henry Ford College, Loughborough University19th March 2008
Sonochemistry Centre at Coventry University “The Home of Sound Science”
AgendaAgenda1.Surface Modification in Electronic Manufacturing
Problems associated with traditional methods
2.What is SonochemistryAcoustic cavitation
Advantages for surface modification
3.Sonochemical Surface Modification
Screening
Optimisation
Scale-up
4. Evolution of the project
5. Lean, Green and Clean Processing?
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Traditional Traditional ‘‘WetWet’’ Surface ModificationSurface Modification
Chemistry Time / min Temp / ºCSolvent Swell 5-15 65-85Rinse 2-6Rinse 2-6Permanganate Etch 5-15 75-85Rinse 2-6Rinse 2-6Neutralizer 3 RT-50Rinse 1-2Rinse 1-2
•Relatively long dwell times
•3 stage process
•High Temperatures required
•High energy costs
•Copious rinsing
•High water costs
Example Example -- DesmearingDesmearing of PCBof PCB’’s or Adhesion Promotion of s or Adhesion Promotion of MIDsMIDs
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Traditional Traditional ‘‘WetWet’’ Surface ModificationSurface Modification
Substrates Chemistry HazardsPCBs, MIDs other polymers
Solvent Swell VOC, flammable
PCBs, MIDs other polymers
Alkaline Permanganate
Highly caustic, strong oxidant
ABS Chromic acid Carcinogenic, highly acidic
Ceramics, glass Hydrofluoric acid Causes burns, targets bone
•Hazardous Chemistry
•VOC’s, carcinogens, corrosive
•Environmental and health and safety legislation
•High Waste Treatment costs
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Traditional Traditional ‘‘WetWet’’ Surface ModificationSurface Modification SummarySummary
Traditional surface modification processes characterised by…..
•Long process times
•High temperature baths
•High water usage
•Hazardous chemistry
CAN SONOCHEMISTRY HELP ?
Sonochemistry Centre at Coventry University “The Home of Sound Science”
SonochemistrySonochemistryThe effect of sound on the chemistry of a solution
I I I I I I I I 0 10 10 10 10 10 10 10
2 3 4 5 6 7
Human hearing 16Hz - 18kHz
Conventional power ultrasound 20kHz - 100kHz
Extended range for sonochemistry 20kHz - 2MHz
Diagnostic ultrasound 5MHz - 10MHz
THE FREQUENCY RANGES OF SOUND
I I I I I I I I 0 10 10 10 10 10 10 10
2 3 4 5 6 7
Human hearing 16Hz - 18kHz
Conventional power ultrasound 20kHz - 100kHz
Extended range for sonochemistry 20kHz - 2MHz
Diagnostic ultrasound 5MHz - 10MHz
THE FREQUENCY RANGES OF SOUND
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface Modification Acoustic Acoustic CavitationCavitation
5000 oC2000 ats
bubbleforms
bubble grows in successive cycles
reachesunstable size
undergoesviolent collapse
compression compression
rarefactionrarefaction rarefaction rarefaction rarefaction
compression compression
5000 oC2000 ats5000 oC2000 ats
bubbleforms
bubble grows in successive cycles
reachesunstable size
undergoesviolent collapse
compression compression
rarefactionrarefaction rarefaction rarefaction rarefaction
compression compressioncompression compression
rarefactionrarefaction rarefaction rarefaction rarefaction
compression compression
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface Modification Generation of Oxidizing Species
Chemicals break down in the cavitation bubble
Sonochemical decomposition of water
H2 O →
Ho + OHo
Ho + O2 →
HO2o
HO2o + HO2
o →
H2 O2 + O2
OHo + OHo →
H2 O2
OHo (Hydroxyl radical) – short lived
HO2o (Perhydroxyl radical) – short lived
H2 O2 (Hydrogen Peroxide)
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface Modification MicrojettingMicrojetting at a solid surfaceat a solid surface
surface cleaningdestruction of boundary layersurface activationimproved mass and heat transfer
boundary layer
solid surface
Collapse at or near a solid surfaceInrush of liquid from one side of the collapsing bubble
produces powerful jet of liquid targeted at surface
surface cleaningdestruction of boundary layersurface activationimproved mass and heat transfer
surface cleaningdestruction of boundary layersurface activationimproved mass and heat transfer
boundary layer
solid surface
Collapse at or near a solid surfaceInrush of liquid from one side of the collapsing bubble
produces powerful jet of liquid targeted at surface
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface Modification MicrojettingMicrojetting at a solid surfaceat a solid surface
Prof. L.A. Crum, University of Seattle
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface Modification
• Microjetting– Mechanical/physical attack of surface– Scrubbing/cleaning action– Destruction of boundary layers– Movement of reactants to, and
products/debris away from, the surface• Extreme temperatures and pressures
– Chemical/oxidative attack of the surface due to oxidative species
– Breaking of bonds on surface of material– Chemical reactions on surface
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface Modification Feasibility StudyFeasibility Study
Isola 370HR – Tg 180 ºC
Materials Tested
Cycolac S705 – ABS/PC
Noryl HM4025 – Polyphenylene ester / polystyreneCourtesy of Moulded Circuits
Ceramic Material
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Experimental SetSonochemical Experimental Set--upup20 kHz Ultrasonic probe
Water in
Water out
Water Jacket
Solution
Sample holder
Sample
Thermostat
•All experiments performed at 40 ºC
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface Modification Sonochemical Surface Modification –– ScreeningScreening
Effect of Ultrasound on Existing Surface Modification Processes
DI Water 400g/l Potassium Hydroxide
10% Sulphuric acid 5g/l AB42
10% Sulphuric acid, 5% Hydrogen peroxide 150g/l AB42
20% Nitric acid Alkaline Permanganate
20% Nitric acid, 40% Phosphoric acid 75ml/l Nitric acid, 27g/l Potassium permanganate
40% Phosphoric acid 20% Hydrogen peroxide
85% Phosphoric acid, 5g/l Potassium permanganate 27g/l Potassium persulphate
20% Ammonia, 40% Hydrogen peroxide 27g/l Potassium persulphate + 5g/l Ferrous Sulphate
8.2% Hydrochloric acid, 8.2% Hydrogen peroxide 4.1% Hydrochloric acid, 4.1% Hydrogen peroxide
•Reduce chemical concentrations
•Reduce process times
•Reduce temperatures
Sonochemistry Centre at Coventry University “The Home of Sound Science”
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
0.00
0.05
0.10
0.15
0.20
Wei
ght L
oss
(mg/
cm2 )
Solution Code
Without UltrasonicsWith ultrasonics
Sonochemical Surface ModificationSonochemical Surface Modification Effect of Ultrasound on Existing Surface Modification Processes
Weight loss results for Ceramic Material
DI Water
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface Modification Sonochemical Surface Modification OptimisationOptimisation
Sonochemical Surface Modification in DI water
Evaluate the effect of Sonication time on Surface Modification
Determine Efficacy by various surface analysis techniques
•Weight loss
•Contact Angle
•Roughness (Stylus profilometer)
•SEM
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface Modification of Noryl HM4025Sonochemical Surface Modification of Noryl HM4025 Effect of Sonication time on weight loss
20 kHz Ultrasonics Horn, Power 33.5 W, 40 ºC, DI Water
0.0000
0.0500
0.1000
0.1500
0.2000
0.2500
0 10 20 30 40 50 60 70
Time (minutes)
Wei
ght L
oss
(mg/
cm2 )
As received
30 minutes sonication
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface Modification of CeramicSonochemical Surface Modification of Ceramic Effect of Sonication time on weight loss
20 kHz Ultrasonics Horn, Power 33.5 W, 40 ºC, DI Water
0.0000
0.0500
0.1000
0.1500
0 10 20 30 40 50 60 70Time (minutes)
Wei
ght L
oss
(mg/
cm2 )
As received
30 minutes sonication
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface Modification of Sonochemical Surface Modification of IsolaIsola 370HR370HR Effect of Sonication time on weight loss
20 kHz Ultrasonics Horn, Power 33.5 W, 40 ºC, DI Water
0.0000
0.0500
0.1000
0.1500
0.2000
0.2500
0.3000
0 10 20 30 40 50 60 70
Time (minutes)
Wei
ght L
oss
(mg/
cm2 )
As Recieved
30 minutes Sonication
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface Modification Sonochemical Surface Modification –– Phase 2 Phase 2
Conclusions• Sonochemical Surface Modification of Isola 370HR, Noryl
HM4025 and Ceramic is possible in DI water• Degree of surface modification tends to increase with
sonication time• Little effect on ABS – some very localised surface
modificationFurther work• Optimisation of sonochemical parameters
– Power– Frequency– Viscosity
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface Modification Scale-up
Surface Modification of a Ceramic
0.0000
0.0200
0.0400
0.0600
0.0800
5 minutes 15%HF Etch
5 minutes 150W 5 minutes 150W+ Surfactant
10 minutes150W
10 minutes150W +
Surfactant
Wei
ght l
oss
(mg/
cm2 )
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface Modification Sonochemical Surface Modification –– Scale up Scale up
Work in progress….• Scale up appears to be feasible• Confirms that sonochemical surface
modification can be achieved in tap water• Weight loss significantly higher than HF etch• Adding a small amount of surfactant is
beneficial to the process• Need to optimise ‘jigging’ of material
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Evolution of the Sonochemical Surface Modification ProjectEvolution of the Sonochemical Surface Modification Project
Concept
Use Ultrasound to Enhance existing surface modification techniques
Sonochemical Surface
Modification in water
Optimisation of sonochemical
paramaters
Scale up
Other Ultrasound techniques
Abrasive particles Sonoelectrochemical
Spin off projects
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface ModificationA route to Lean, Green and Clean
Manufacturing ?
LEANOne stage process
GREENLower temperatures, reduced energy costs, less rinsing, lower
waste treatment costs.
CLEANNon-hazardous chemistry
Sonochemistry Centre at Coventry University “The Home of Sound Science”
The Sonochemistry Centre at Coventry UniversityFaculty of Health and Life Sciences
Coventry UniversityCoventry, CV1 5FB, UK
www.coventry.ac.uk/sonochemistry
CONTACT DETAILSCONTACT DETAILS
[email protected] - +44 (0) 24 76 888 624
Mobile – 07706 955 901Fax +44 (0) 24 76 888173
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Sonochemical Surface ModificationSonochemical Surface ModificationProject funded by
Industrial Partners
MOULDED CIRCUITS LTD
Laminate supplied by………
Sonochemistry Centre at Coventry University “The Home of Sound Science”
Thank youThank you
Any Questions ?