Why is Durostone the Ideal Material for Wave Solder Pallet?

Durostone is is a high-performance fiber-reinforced composite material developed by Germany's Röchling Group, which is composed of thermosetting resin (such as epoxy or polyester resin) and glass fiber mat reinforcement, and processed through high-pressure lamination, pultrusion and other processes. It stands out for its excellent high-temperature resistance, dimensional stability, anti-static properties and chemical corrosion resistance, and is widely used in high-demand industrial fields such as electronics manufacturing, aerospace and automotive industry.

The durostone sheet is the ideal material for wave soldering trays because of its high compatibility with the process requirements. It can withstand the high temperature and chemical corrosion of the soldering process, ensure the positioning accuracy of PCB and the safety of components, and balance cost and durability.

1. High temperature resistance and thermal stability

The wave soldering bath temperature typically ranges from 240 to 260°C (up to 280°C for lead-free processes), with the pallet repeatedly traversing high-temperature zones. The thermal properties of durostone sheet perfectly meet these requirements.

High-temperature durability: Standard durostone sheet can operate continuously at 260-280°C, while premium models withstand short-term exposure to 350-380°C—far exceeding the peak temperature of wave soldering without melting, softening, or delamination.

Low thermal expansion coefficient: The thermal expansion coefficient of durostone is only 1/5~1/3 of ordinary bakelite and aluminum alloy. The deformation amount at high temperature is extremely small (≤0.1mm/m), which can accurately fix the PCB and avoid the pad shift, bridge or false soldering caused by the deformation of the pallet.

Low thermal conductivity: The thermal conductivity of the durostone is low (0.3~0.5W/ (m·K)), which can reduce the heat transfer to the non-welded area of the PCB and protect the thermosensitive components (such as LED, electrolytic capacitor) from high temperature damage.

2. Chemical Corrosion Resistance and Resistance to Flux Erosion

Rosin and halogen activators are used in wave soldering fluxes, which are corrosive and generate acidic vapors at high temperatures. The resin-based material of durostone (e.g., phenolic resin, epoxy resin) exhibits excellent chemical inertness, resisting solder flux corrosion without surface bubbling, slagging, or fiber exposure.

Compared with conventional FR-4 boards, durostone exhibit 3-5 times longer corrosion resistance, effectively reducing PCB contamination from pallet damage (e.g., fiber debris adhering to solder pads) and lowering soldering defect rates.

3. Anti-static Characteristics and Protection of Sensitive Electronic Components

PCB components like chips and sensors are highly sensitive to static electricity (with breakdown thresholds as low as a few hundred volts). The anti-static design of durostone effectively mitigates this risk.

The surface resistance of durostone is stable at 10⁵~10⁹Ω (conforming to the anti-static standard of electronic manufacturing), which can quickly conduct the static electricity generated by friction and avoid the accumulation of static electricity to break down the components.

No additional anti-static coating is required (as the coating tends to peel off at high temperatures), ensuring long-lasting anti-static performance and suitability for prolonged cyclic use.

4. Mechanical Strength + Machinability

The wave soldering pallet must provide adequate rigidity to support the PCB while incorporating precision openings and positioning grooves. The durostone's mechanical properties can effectively meet both requirements.

High rigidity and impact resistance: The durostone sheet has a bending strength of 150-250 MPa, capable of withstanding impacts during PCB loading and conveyor transportation, while resisting cracking or deformation.

High-precision machining: Achieves ±0.05mm accuracy through CNC milling and laser cutting, meeting the exacting requirements for pad openings and positioning pin grooves, with smooth edges free of burrs (preventing PCB scratches).

Lightweight: the specific gravity is only 1.6~2.0g/cm3, much lighter than the aluminum alloy pallet, reducing the conveyor load and equipment wear.

5. Balance of cost and durability

Compared with other wave soldering pallet materials, durostone demonstrates a significant advantage in overall cost-effectiveness.

Long service life: Conventional synthetic stone pallets can withstand 3,000 to 6,000 furnace cycles, while high-end models exceed 10,000 cycles.

Cost-effectiveness: The unit price is merely 1/3 to 1/5 of imported Durostone and half that of aluminum alloy, with no frequent replacement required. Its long-term usage cost is significantly lower than other materials.

Easy maintenance: The smooth surface resists solder and flux adhesion, requiring only isopropanol wiping for cleaning, with low maintenance costs.

6. Versatile compatibility to meet diverse PCB soldering requirements

For thin PCBs and flexible FPCs, hollow support structures can be designed to balance rigidity and lightweight.

For high-density PCBs: Capable of machining ultra-fine apertures (with diameters ≥0.5mm) to precisely align with micro pads.

For specialized component protection: The system can integrate silicone/PTFE inserts to further enhance the protective efficacy of sensitive components.

RDS Composite provide wave soldering pallet materials and custom-made wave soldering pallets with extremely high precision to meet the strict requirements of various electronic manufacturing applications. Our products are carefully managed from raw material procurement through the entire production process to ensure they meet international standards. We are committed to providing you with reliable quality products and timely delivery of services.