Composite coatings for whisker reduction

Abstract

There is provided a method and composition for applying a wear resistant composite coating onto a metal surface of an electrical component. The method comprises contacting the metal surface with an electrolytic plating composition comprising (a) a source of tin ions and (b) non-metallic particles, and applying an external source of electrons to the electrolytic plating composition to thereby electrolytically deposit the composite coating onto the metal surface, wherein the composite coating comprises tin metal and the non-metallic particles.

1 . A method for applying a composite coating onto a metal surface of an electrical component, the method comprising:
 contacting the metal surface with an electrolytic plating composition comprising (a) a source of tin ions and (b) a pre-mixed dispersion of non-metallic particles having a mean particle size between about 10 and about 500 nanometers, wherein the non-metallic particles have a pre-mix coating of surfactant molecules thereon; and   applying an external source of electrons to the electrolytic plating composition to thereby electrolytically deposit the composite coating onto the metal surface, wherein the composite coating comprises tin and the non-metallic particles.   
   
   
       2 . The method of  claim 1  wherein the non-metallic particles are fluoropolymer particles. 
   
   
       3 . The method of  claim 2  wherein the pre-mixed dispersion comprises fluoropolymer particles and a non-ionic surfactant. 
   
   
       4 . The method of  claim 2  wherein the pre-mixed dispersion comprises fluoropolymer particles, a non-ionic surfactant, and a cationic surfactant. 
   
   
       5 . The method of  claim 2  wherein the fluoropolymer particles constitute between about 1 wt % and about 10 wt % of the electrolytic plating composition. 
   
   
       6 . The method of  claim 2  wherein the source of tin ions is sufficient to provide a concentration of Sn ions between about 10 g/L and about 100 g/L. 
   
   
       7 . The method of  claim 2  wherein the source of tin ions sufficient to provide a concentration of Sn 2+  ions of between about 10 g/L and about 100 g/L, the fluoropolymer particles constitute between about 1 wt % and about 10 wt % of the electrolytic plating composition, the electrolytic plating composition has a pH between about 0 and about 3, at least about 80 volume % of the fluoropolymer particles have a particle size of less than 200 nm, and the composite coating comprises between about 1 wt % and about 5 wt % of the fluoropolymer particles. 
   
   
       8 . A method for applying a composite coating onto a metal surface of an electrical component, the method comprising:
 contacting the metal surface with an electrolytic plating composition comprising (a) a source of tin ions and (b) non-metallic particles having surfactant coatings, wherein the surfactant coatings have an average charge per surfactant molecule of between +0.1 and +1; and   applying an external source of electrons to the electrolytic plating composition to thereby electrolytically deposit the composite coating onto the metal surface, wherein the composite coating comprises tin and the non-metallic particles.   
   
   
       9 . The method of  claim 8  wherein the non-metallic particles are fluoropolymer particles having a mean particle size between about 10 and about 500 nanometers. 
   
   
       10 . The method of  claim 9  wherein the fluoropolymer particles constitute between about 1 wt % and about 10 wt % of the electrolytic plating composition. 
   
   
       11 . The method of  claim 9  wherein the source of tin ions is sufficient to provide a concentration of Sn ions between about 10 g/L and about 100 g/L. 
   
   
       12 . The method of  claim 9  wherein the source of tin ions sufficient to provide a concentration of Sn ions of between about 10 g/L and about 100 g/L, the fluoropolymer particles constitute between about 1 wt % and about 10 wt % of the electrolytic plating composition, the electrolytic plating composition has a pH between about 0 and about 3, at lest about 80 volume % of the fluoropolymer particles have a particle size of less than 200 nm, and the composite coating comprises between about 1 wt % and about 5 wt % of the fluoropolymer particles. 
   
   
       13 . A method for applying a Sn-based composite coating onto a metal surface of an electrical component, the method comprising:
 contacting the metal surface with an electrolytic plating composition comprising (a) a source of tin ions sufficient to provide a concentration of Sn 2+  ions of between about 10 g/L and about 100 g/L, (b) an acid in a concentration sufficient to impart a composition pH between about 0 and about 3, and (c) a pre-mixed dispersion of non-metallic particles having a mean particle size between about 10 and about 500 nanometers and having a pre-mix surfactant coating thereon, to provide a concentration of non-metallic particles of between about 1 wt. % and about 10 wt. % of the electrolytic plating composition; and   applying an external source of electrons to the electrolytic plating composition to thereby electrolytically deposit the composite coating onto the metal surface, wherein the composite coating comprises tin and the non-metallic particles.   
   
   
       14 . The method of  claim 13  wherein the non-metallic particles comprise fluoropolymer particles. 
   
   
       15 . The method of  claim 14  wherein the surfactant coating is predominantly positively charged. 
   
   
       16 . The method of  claim 14  wherein the surfactant coating comprises a cationic surfactant, a non-ionic surfactant, or a combination thereof. 
   
   
       17 . The method of  claim 13  wherein the electrolytic plating composition further comprises a source of Bi 3+  ions, a source of Zn 2+  ions, a source of Ag +  ions, a source of Cu 2+  ions, a source of Pb 2+  ions, and combinations thereof. 
   
   
       18 . A method for applying a composite coating onto a metal surface of an electrical component, the method comprising:
 contacting the metal surface with an electrolytic plating composition comprising (a) a source of tin ions and (b) a pre-mixed dispersion of fluoropolymer particles having a mean particle size between about 10 and about 500 nanometers; and   applying an external source of electrons to the electrolytic plating composition to thereby electrolytically deposit the composite coating onto the metal surface, wherein the composite coating comprises tin and between about 1 wt. % and about 5 wt. % of the fluoropolymer particles.   
   
   
       19 . A method for applying a composite coating onto a metal surface of an electrical component, the method comprising:
 contacting the metal surface with an electrolytic plating composition comprising (a) a source of tin ions and (b) non-metallic particles, wherein the non-metallic particles are characterized by a particle size distribution in which at least about 30 volume % of the particles have a particle size less than 100 nm; and   applying an external source of electrons to the electrolytic plating composition to thereby electrolytically deposit the composite coating onto the metal surface, wherein the composite coating comprises tin and the non-metallic particles.   
   
   
       20 . The method of  claim 19  wherein the non-metallic particles comprise fluoropolymer particles characterized by a particle size distribution in which at least about 80 volume % of the particles have a particle size less than 200 nm.