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The Conformal Coating Journey

Explore the history, market share, and factors influencing trends in conformal coatings. Learn about test specification evolution, cost arguments, and the latest technologies driving reliability and performance. Discover the global market share, industry growth areas, and test specification changes that impact electronic devices.

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The Conformal Coating Journey

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  1. The Conformal Coating Journey Marie KaingKey Account Manager

  2. Summary • History of Conformal Coating • Current global market share • Factors influencing industry trends • Test specification evolution

  3. History of Conformal Coating

  4. History of Conformal Coating • 50 years- Parylene (Vacuum deposition) • Protection with thin layer (25-75microns) • Technology reserved for high reliability military and aerospace • Only the most expensive PCB coated • Material + process = Too high cost

  5. History of Conformal Coating • Electronics becoming more fragile due to: • Circuit size reduction • Higher component densities • Increased features & capabilities • Cheaper circuit costs, • Constant growing need for more protection • Expanded use of Conformal Coatings  Developments of new technologies, new needs for new markets

  6. Reliability • Reliability is becoming a “must have” for today’s electronic devices • Demands are filtering down to everyday consumer goods • Conformal Coating enable to: • Reduce premature failure • Provide longer warranty • Enhance perception of quality  What is the cost argument?

  7. Reliability cost • Electronic for a car radio • Apply a Conformal Coating: • PCB size: 100mmX100mm • Material volume/board: 100mmX100mmX0.050mm = 0.5cm3 • Material cost/board= €0.06 • Labour&equip/board = €0.02 • Total approx coating cost = €0.10/board

  8. Reliability cost • Without a conformal coating • 1 field failure = €130 to replace the radio (€60 radio + €70 labour) • Coating costs equate to 1 field failure in 1300 boards • Coating costs equate to 0.1% of radio cost

  9. Evolution of Technologies Today 5o years ago Tomorrow Parylene Solvent based acrylic ?

  10. Conformal Coating Global Market

  11. Global market value of conformal coatings Source BCC Research

  12. Global market share by application Source BCC Research

  13. Market segment growth areas • Automotive • Industrial Controls • White Goods • LED signage systems • Consumer electronics

  14. Global market share by region Source BCC Research

  15. Global market share by product Source BCC Research

  16. Factors affecting industry trends

  17. Factors influencing industry trends

  18. Cost performance expectations HIGH cost HIGH performance HIGH cost LOW performance Cost FUTURE PAST FUTURE LOW cost HIGH performance LOW cost LOW performance Performance

  19. Test Specifications Evolution

  20. Test specifications origins • Standards and specifications provide benchmarks to the industry to maintain a certain level of quality on CC • 1960: MIL-I-46058C 1st conformal coating standard • 1984: IPC-CC-830  commercial version of Mil spec • Relatively easy to pass • All conformal coatings pass MIL and IPC spec.

  21. Test specifications evolution • Changes in specifications are being driven by: • Increasing use of electronics in unusual environments. • Generate industry competitiveness • For example: • Greater Tshock • More fuels/vapors/chemicals exposure • Corrosive atmospheres • Higher temperature excursions

  22. Example of harsher test conditions • MIR test: 164h  500h  1000h  1500h • T-shock: 100cycles  500cycles  1000cycles  1649cycles • Visual inspection done under stronger magnification ie 40X instead of 10X • Total water immersion test

  23. IPC test IPC-CC-830 specification

  24. Customer test Customer specification IPC-CC-830 specification

  25. Individual test sequence Different boards go through each test sequence Temperature cycle Visual inspection Visual inspection Thermal shock Visual inspection Humidity cycle Visual inspection Salt spray test

  26. Cumulative test sequence Same board goes through the entire test sequence Temperature cycle Visual inspection MIR test Damp heat Humidity cycle Salt spray test Thermal shock

  27. Example of new test spec • New CL12 test for Peugeot and Volvo: • Cumulative test on PCB: • Thermal shock: 500 cycles (-40C+125C) • Spray test with drops of acid solution • 85/85 for 1000 hours under 50V  Today there is no conformal coating in the market capable of passing this new test specification

  28. Evolution of Technologies Today 5o years ago Tomorrow Parylene Solvent based acrylic ?

  29. Evolution of Technologies Tomorrow UV Today 5o years ago Solvent based acrylic WATERBASED Parylene SILICONE

  30. Conformal Coating trends3 solvent free solutions • UV curable: Fast curing and chemical resistance • Silicone: Superior flexibility and waterproofness • Water based: Dipping application Material choice is a compromise Today the perfect Conformal coating does not exist

  31. Thank you for your attention

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