What is Popcorn Effect in PCBA Process

Introduction to Popcorn Effect in PCBA

The Printed Circuit Board Assembly (PCBA) process involves several stages, from the design and fabrication of the PCB to the assembly of components onto the board. One of the challenges faced during the PCBA process is the “Popcorn Effect,” a phenomenon that can cause significant damage to the components and the board itself. In this article, we will explore the Popcorn Effect in detail, including its causes, effects, and prevention methods.

What is the Popcorn Effect?

The Popcorn Effect, also known as the “Moisture Induced Stress” or “Moisture Induced Delamination,” is a phenomenon that occurs when moisture trapped inside the plastIC Packaging of electronic components expands rapidly during the reflow soldering process. This rapid expansion of moisture can cause the package to crack or even explode, resulting in damage to the component and the surrounding area on the PCB.

The term “Popcorn Effect” comes from the audible popping sound that can be heard when the moisture expands and causes the package to rupture. The effect is similar to the popping of popcorn kernels when heated.

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” alt=”” class=”wp-image-136″ >

Causes of the Popcorn Effect

The primary cause of the Popcorn Effect is the presence of moisture inside the plastic packaging of electronic components. This moisture can come from various sources, including:

1. Humidity in the storage environment
2. Improper handling and storage of components
3. Inadequate drying of components before assembly
4. Condensation during the reflow soldering process

When the moisture-laden components are subjected to the high temperatures of the reflow soldering process, the moisture expands rapidly, leading to the Popcorn Effect.

Effects of the Popcorn Effect

The Popcorn Effect can have several negative consequences on the PCBA process and the final product:

1. Component damage: The rapid expansion of moisture can cause the component package to crack, exposing the internal circuitry and leading to electrical failures.
2. Board damage: In severe cases, the exploding component can damage the surrounding area on the PCB, causing shorts, opens, or lifted pads.
3. Reliability issues: Even if the component survives the initial Popcorn Effect, the stress induced by the moisture expansion can lead to latent defects and reduced reliability of the component over time.
4. Rework and repair: Damaged components and boards may require rework or repair, increasing production costs and delays.
5. Product failure: If the Popcorn Effect goes undetected during the PCBA process, it can lead to product failures in the field, damaging the manufacturer’s reputation and leading to costly recalls.

Preventing the Popcorn Effect

To minimize the risk of the Popcorn Effect during the PCBA process, several preventive measures can be taken:

1. Proper Storage and Handling

Electronic components should be stored in a controlled environment with low humidity (typically below 60% RH) and at a stable temperature. Proper handling procedures, such as using moisture barrier bags (MBBs) and desiccants, can help protect the components from moisture absorption during storage and transportation.

2. Moisture Sensitivity Level (MSL) Classification

Components are classified according to their Moisture Sensitivity Level (MSL), which determines their susceptibility to moisture-induced damage. The MSL classification ranges from 1 (least sensitive) to 6 (most sensitive). Manufacturers should follow the handling and storage guidelines specified for each MSL class to minimize the risk of the Popcorn Effect.

3. Baking and Drying

Components that have absorbed moisture must be baked and dried before the reflow soldering process. The baking process involves exposing the components to elevated temperatures (typically 125°C) for a specified duration (usually 24 hours) to remove the absorbed moisture. Manufacturers should follow the baking guidelines provided by the component supplier or the IPC/JEDEC standards.

4. Moisture-Sensitive Device (MSD) Handling

Moisture-Sensitive Devices (MSDs) require special handling procedures to prevent moisture absorption. These procedures include:

• Storing MSDs in sealed moisture barrier bags with desiccants
• Limiting the exposure time of MSDs to ambient conditions (out of bag)
• Tracking the exposure time using humidity indicator cards (HICs) or time-sensitive labels
• Re-bagging or baking MSDs if the exposure time exceeds the specified limit

5. Reflow Profile Optimization

The reflow soldering profile should be optimized to minimize the risk of the Popcorn Effect. This involves controlling the ramp rate, peak temperature, and time above liquidus (TAL) to reduce the thermal stress on the components. Manufacturers should follow the reflow profile guidelines provided by the component supplier or the IPC/JEDEC standards.

Detecting the Popcorn Effect

Despite the preventive measures, the Popcorn Effect may still occur during the PCBA process. Detecting the Popcorn Effect is crucial to prevent affected products from reaching the market. Some methods for detecting the Popcorn Effect include:

1. Visual inspection: Cracked or exploded component packages can be detected through visual inspection during the PCBA process or final product inspection.
2. X-ray inspection: X-ray imaging can reveal internal damage to the components, such as delamination or die cracks, which may not be visible through external inspection.
3. Acoustic emission monitoring: The audible popping sound associated with the Popcorn Effect can be detected using acoustic emission sensors during the reflow soldering process.
4. In-circuit testing (ICT): Electrical testing methods, such as in-circuit testing, can detect functional failures caused by the Popcorn Effect.

Repairing Popcorn Effect Damage

If the Popcorn Effect is detected during the PCBA process, the affected components and boards may require repair or rework. The repair process typically involves:

1. Removing the damaged component: The cracked or exploded component is carefully removed from the PCB using desoldering techniques.
2. Cleaning the PCB: The affected area on the PCB is cleaned to remove any residue or debris from the damaged component.
3. Replacing the component: A new component is soldered onto the PCB, ensuring proper alignment and connection.
4. Retesting the board: The repaired board is retested to verify its functionality and ensure that the Popcorn Effect has been successfully resolved.

FAQs

1. Can the Popcorn Effect occur in leadless packages?

Yes, the Popcorn Effect can occur in leadless packages, such as QFNs and BGAs. In fact, leadless packages are more susceptible to moisture-induced damage due to their smaller size and reduced lead pitch.

2. How long can components be exposed to ambient conditions before requiring baking?

The allowable exposure time (floor life) depends on the component’s Moisture Sensitivity Level (MSL) classification. Components with higher MSL classes have shorter floor life and require baking sooner than those with lower MSL classes. Refer to the MSL table in the “Preventing the Popcorn Effect” section for more information.

3. Can the Popcorn Effect occur during wave soldering?

While the Popcorn Effect is more common during reflow soldering, it can also occur during wave soldering if moisture-laden components are exposed to the high temperatures of the molten solder wave.

4. How can I determine a component’s Moisture Sensitivity Level (MSL)?

The MSL classification is typically provided by the component manufacturer in the product datasheet or on the packaging label. If the information is not readily available, contact the manufacturer’s technical support for guidance.

5. Can the Popcorn Effect be detected through functional testing?

Functional testing may not always detect the Popcorn Effect, as the damaged component may still operate within specifications initially. However, the latent defects caused by the Popcorn Effect can lead to premature failure of the component or the entire product. It is crucial to detect and address the Popcorn Effect during the PCBA process through visual inspection, X-ray imaging, or acoustic emission monitoring.

Conclusion

The Popcorn Effect is a serious concern in the PCBA process, as it can lead to component damage, board damage, and product failures. Understanding the causes and effects of the Popcorn Effect is essential for implementing effective prevention and detection methods. By following proper storage and handling procedures, adhering to MSL classifications, and optimizing the reflow soldering profile, manufacturers can minimize the risk of the Popcorn Effect and ensure the reliability of their products. Regular inspection and testing during the PCBA process can help identify any instances of the Popcorn Effect, allowing for timely repair and rework. Addressing the Popcorn Effect is crucial for maintaining product quality, reducing production costs, and safeguarding the manufacturer’s reputation in the market.