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Improving Reliability of High Performing PCB With Advanced Conformal Coating Use
The paper discusses a newly developed conformal coating system that meets the high performance, reliability and cycle time demand based on the hybrid polymer approach.
Technical Paper
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Authored By:
Rita Mohanty, Alejandro Sanchez, Paul Minagawa
Henkel Corporation
MN, USA
Summary
Recent growth in power electronics has fueled the innovation of Printed Circuit Board (PCB) protecting solutions to ensure smooth operation and reliability of these expensive boards and electronics components. Current PCB design used in Power & Industrial applications, Automotive, Military, Telecommunication, etc. needs stronger protection than ever to protect the boards from harsh external environment. Conformal coating has been used to protect PCB from harsh environment for decades. However, the new high power and complex board designs need a level of protection with circular economies in mind that is not achievable with the existing solutions.
Conformal coating is a chemical coating that is applied to the PCB to conform to the surface topography and act as a barrier against corrosion from external environment. Conventional conformal coatings are based on single polymer systems that may contain solvent for ease of application. Solvents in the system create environmental concerns and increase production cycle times. This has created an opportunity to develop solvent free, hybrid polymer systems that not only meet the performance and reliability needs of complex boards but also meet the emission standards set by various countries.
In this paper we will discuss a newly developed conformal coating system that meets the high performance, reliability and cycle time demand based on the hybrid polymer approach (Urethane Acrylates). Results from a structured Design of Experiment (DOE) using a standard test vehicle will be presented. In addition to the product characterization, reliability test results will be shared. The characterization tests will include agencies tests, such as UL and IPC, for conformal coating.
Conclusions
Demand for ultra-fast charging station, on-board chargers for vehicles, 5G infrastructure, datacenter and many industrial applications requires a level of PCB protection that didn’t exist before. Along with the protection against the corrosive environment, higher level of health and safety standards must be met. In this body of work, we have tested a new product from Henkel (LOCTITE STYCAST CC8555) to characterize and assess reliability under harsh environmental in compared to commercially available conformal coatings.
Based on the results we can conclude that the new hybrid chemistry meets key agency standards such as UL 94V0, UL RTI rating of 130°C and IPC 830B status. MFG test results show that CC8555 shows no sign of corrosions. Further, reliability test results shows that the CC8555 shows no cracking or significant delamination after 1000 hours of thermal cycling from -40°C to 125°C. Compared to the older generation of conformal coating, the new hybrid system shows significant improvement in reliability and high temperature safety standards. This is critical for high power and high voltage applications.
We continue to analyze the data from reliability DOE and plan to publish this at a later time. Additional experimental studies are ongoing to evaluate industry leading hybrid conformal coating to provide the end users to select the right coating for their applications. As a next step, we will continue to conduct additional study to further understand the reliability and performance against similar coatings.
Initially Published in the SMTA Proceedings
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