The use of adhesive technology in the replacement of solder for the manufacture of the new Fiat 500 ignition system

A collaboration between Magneti Marelli and Ablestik Electronic Materials and Adhesives has resulted in the manufacture of an electronic ignition system which is free from lead containing component joints in addition to an `Ozone Depleting Substances free´ process. The key to manufacture is the use of a conductive polymer component attach. Furthermore, this provides a joint which is reliable when subjected to severe environmental stresses. Ablebond 8175 electrically conductive adhesive has been developed to screen print to 375 μm resolution with stress relieving properties which provide stability under extreme thermal conditions. Details of extensive testing performed to establish the feasibility of various materials are discussed, detailing results after thermal and mechanical shock, thermal fatigue, temperature cycling, and vibrational testing using a range of components. Finally, Nanoplex units are produced using Ablebond 8175 and tested for long-term reliability. Nanoplex was then approved for production in the new Fiat 500 ignition system