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Conformal Coating Removal - How to Get Started W/Reference

Oct 10, 2024

Conformal coatings are polymeric films on printed circuit boards (PCBs) that protect against hazards like moisture, pollution, chemicals, and temperature changes. This layer of..

Polyurethane Conformal Coatings - Benefits & Applications

Oct 02, 2024

Conformal coatings are polymeric materials applied to a PCB to improve device reliability. These films protect electronics from environmental threats, including humidity, liquids,..

An Overview of Our Parylene Coating Equipment

Sep 26, 2024

The development of our coating technology began in 2007. We've come a long way since, filing more than 200 patents and protecting millions of digital devices. Today, we want to..

Parylene Biocompatibility - Parylene Compared, Analyzed For Medical

Sep 24, 2024

Biocompatibility is vital to medical device safety. It ensures implants and other devices can be used in and on the body with minimal adverse reactions. Medical devices must be..

Parylene Coating Removal - Methods & Best Practices for Each

Sep 12, 2024

Parylene coatings present unique challenges when it comes to rework and removal. They often outperform other conformal coatings. Parylene has better barrier properties, uniform..

MIL-I-46058C: Definitive Guide to Military Standards for PCBAs

Aug 06, 2024

Reliability is a top priority in defense and aerospace electronics in harsh, unforgiving environments. The MIL-I-46058C standard is a guideline for conformal coating materials..

Polymer Glass Transition Temperature - Material Properties, Impact

Sep 21, 2023

Polymer glass transition temperature (Tg) refers to the temperature at which an amorphous polymer transitions from a glassy, rigid state to a rubbery, flexible state...

What is Coefficient of Linear Expansion? Formula, Units & More

Sep 21, 2023

Temperature affects the behavior of materials, causing them to expand or contract. However, not all materials respond to temperature variations in the same way. Some materials,..

What is Thermal Conductivity? Explanation, Measurement, Uses

Sep 21, 2023

Thermal conductivity is a fundamental concept in heat transfer and is crucial in multiple industries and scientific disciplines. It refers to the ability of a material to conduct..

$What is the Index of Refraction? Measurement, Definition & More$

What is the Index of Refraction? Measurement, Definition & More

Sep 20, 2023

Understanding how light travels through different mediums is essential in optics. One invaluable optical property is the index of refraction. This measurement quantifies how much..

Tensile Strength at Yield - Testing, Standards, Specs, Material

Sep 19, 2023

The ability to accurately predict the behavior of coating materials under tension is crucial in ensuring the integrity and reliability of electronic components. This includes..

Elongation at Break - Definition, Testing, Material Selection

Sep 19, 2023

Elongation at break is a key mechanical property that measures the deformation capacity of a material before it eventually snaps or breaks, providing insights into the material's..

Young's Modulus of Polymers - Measurement, Calculation

Sep 19, 2023

Young's Modulus is an important property, allowing engineers to select coating materials based on their desired stiffness. Understanding and manipulating the elastic Modulus of..

Water Vapor Transmission Rate - Standards, Testing, Material

Sep 14, 2023

In the world of electronics, moisture control is of utmost importance. High water vapor transmission rate (WVTR) can pose significant risks to sensitive electronic devices. When..

Transparent Polymers - Applications, Material Selection

Sep 14, 2023

Transparent polymers offer optical clarity and the ability to transmit light. With various applications across various industries, these polymers have gained popularity for their..

Biocompatible Coatings - Coating Techniques, Applications, More

Sep 13, 2023

Biocompatible coatings seamlessly integrate with the human body, offering benefits through their ability to promote healing and prevent adverse reactions. They can improve patient..

Dissipation Factor - Definition, Measurement, Variables

Sep 12, 2023

Dielectric materials are crucial in various industries and applications, serving as insulators, substrates, or capacitors. One important characteristic often evaluated in..

Volume Resistivity - Definition, Measurement, Product Design

Sep 12, 2023

Whether designing circuit boards or protecting electrical components, knowledge of the volume resistivity of coating materials plays a pivotal role in creating efficient and..

UL94 Coating Material - Testing Method, Material Selection

Sep 08, 2023

Fire safety compliance is an indispensable aspect across various industries. One crucial benchmark in fire safety compliance is UL94, a widely recognized standard for flammability..

Elongation Yield: Overview, Unit of Measure, Data and Testing

Aug 29, 2023

Elongation yield refers to the maximum amount of deformation a material can undergo before it experiences a permanent change in shape or size. This property is fundamental in..

Difference Between Water Resistant, Repellent, & Proof

Aug 10, 2023

If you're looking for the highest quality protection from the inside out, contact HZO today. We all see references to waterproof, water-resistant, and water-repellant devices..

Top Electronics Manufacturing Industry Publications

Jun 15, 2023

If you work in the electronics manufacturing industry, you are likely plagued with information overload, whether you are an engineer, purchasing professional, or business-oriented..

ADAS Design and Validation for the Real World - Automotive Coatings

Jun 15, 2023

Advanced driver assistance systems (ADAS) continue to expand in features and functionalities. Standard offerings may include adaptive cruise control, park assist, blind-spot..

IP Ratings Decoded: IP57, IPX7, IPX5 Explained

Jun 15, 2023

Download the IP Checklist Download Checklist Download HZO's Ingress Protection (IP) Checklist Your shiny new smartwatch claims to be IP57 waterproof, your new phone claims to be..

Preserving Power: Protective Coatings for EV Battery Corrosion

Jun 15, 2023

EV batteries promise to revolutionize transportation as we know it, but is it all positive? The future of electric vehicles is riding on the dependable operation of these energy..

Engineered Reliability: Conformal Coatings for ECUs

Jun 15, 2023

Quite possibly the most critical systems in modern-day vehicles, electronic control units (ECUs), are responsible for overseeing, regulating, and altering the operation of a car’s..

Parylene Conformal Coatings - Parylene Conformality Explained

Jun 06, 2023

Parylene (p-polyxylylene) conformal coatings are unique due to their capacity to be polymerized and deposited by the chemical vapor deposition (CVD) method onto surfaces near room..

What is Parylene? Industry Use Cases, Types, Properties

Jun 06, 2023

What is Parylene? Is it Right For My Project? Parylene forms high-performance thin-film coatings. There are several types, like Parylene N, C, and D. Each has unique chemical..

Dielectric Constant of Insulator Materials: Formula, Table of Values

Oct 12, 2022

Depending on their formulated ingredients and molecular structures, thin film coatings may be electrically conductive, insulative, or semiconductive. Insulative coatings serve..

What is the Dielectric Strength Formula? Testing, Table of Values

Sep 16, 2022

Although thin film coatings serve many purposes, providing dielectric isolation and electrical insulation is one of the essential functions. Dielectric strength is an important..

Arc Resistance - Concepts and Testing Explained

Aug 12, 2022

Insulating materials such as Teflon, plastic, rubber, ceramic, or glass ensure products function properly and safely. However, no insulator is perfect. These materials still..

Conformal Coating for Drones - Which is Best?

Apr 15, 2022

As technology advances, so do the capabilities of drones, which are available in various sizes, weights, and shapes. The technological advancements in drone specifications,..

Parylene Masking - General Concepts Explained

Jan 28, 2022

Conformal coatings are an excellent way to increase the reliability of electronic components in harsh environments. However, this protection can be too much of a good thing..

How to Make Your Lithium-ion Battery Design More Sustainable

Dec 04, 2021

A recent report from “Markets and Markets” revealed that experts expect the battery recycling market to grow to $23.2 billion by 2025, at a CAGR of 6.1% from 2020-2025. This..

Improving CGM Electronics Designs with Medical Coatings

Nov 20, 2021

A vital issue for continuous glucose monitor development is design and reliability engineering. CGM systems, however, will encounter environments that can jeopardize electronics..

How Much Does Parylene Coating Cost? - All Things Considered

Oct 15, 2021

Parylene coatings are known for robust protection from liquids, corrosion, chemicals, and strong electrical activity at a fraction of the thickness of alternative coatings, such..

PECVD vs CVD – Chemical Vapor Deposition Overview

May 07, 2021

Thin-film deposition is the dynamic process used for depositing thin-film coatings onto a substrate, part, or assembly. Deposition methods, in general, can be grouped into three..

NEMA vs IP Ratings Explained

Apr 14, 2021

Once upon a time, computers only sat perched on desktops, but that is no longer the case. Deployed in harsh industrial, medical, automotive, and consumer household environments,..

How To: A Wearable Device Design That Consumers Actually Want

Mar 20, 2021

Wearable devices provide insight and convenience to consumers through activity tracking and biometric data that they can easily access through a wearable app. But many wearable..

What is Corrosion & Does It Ruin Electronics? How to Remove It?

Oct 15, 2020

Imagine the following scenario: You are washing the dishes, listening to music on your smartphone when suddenly the unthinkable happens – the phone that was nestled safely in your..

IoT - Coating Consistency is Key

Sep 25, 2020

IoT sensors aggregate and send data to IoT dashboards, simplifying critical, complex decisions quickly. One key area where this is particularly true is the utilization of sensor..

Parylene Thickness - Industry Benchmarks, Cost, Effect on Properties

Aug 18, 2020

In the world of protective coatings, Parylene is a standout. Its unique, beneficial properties make it a great choice. Many Parylene types have distinct properties, like Parylene..

6 Common Conformal Coating Defects & Their Solutions

Jun 16, 2020

When we say that a chain is only as strong as its weakest link, we aren’t talking about polymer chains – we’re talking about conformal coating defects. Regardless of the type, a..

Conformal Coating vs Potting/Encapsulation - The Pros & Cons

Jun 11, 2020

As the world of electronics continues to grow and evolve, printed circuit board assemblies (PCBAs) find their way into more and more products and industries. Whether you create..

Epoxy Conformal Coating Evaluation Guide

May 21, 2020

Conformal coatings are polymeric materials applied to substrates. These films protect electronics from environmental hazards, like corrosion, humidity, chemicals, and liquids...

Solving Weather & Water Challenges For Smart Farms

May 12, 2020

It’s a Small World, After All The world’s population is projected to reach 8.5 billion by 2030, an unprecedented increase approaching fast. This looming surge will compound our..

Designing a Waterproof Product With IP Ratings

Mar 25, 2020

The Big Picture: Manufacturers determine IP ratings, not an impartial group. Although these rating systems are useful for comparison purposes, they are not the panacea for rating..

Rakuten Kobo Chooses HZO | Waterproof Next Generation Ereader

Aug 17, 2016

Consumer requests for waterproofing made possible with HZO Technology Draper, UT – August 17, 2016 – HZO Inc., the total solutions leader in liquid and environment protection..

Don't Be Left in the Dark: Brief History of Light Emission Devices

Apr 28, 2015

One of the best things about working for a company like HZO is the opportunity to be exposed to an extremely wide variety of technologies (apart from our own). Our seasoned..

HZO Investor Profile: Delta Electronics Capital

Apr 14, 2015

As HZO prepares for its first Board of Directors meeting of 2015, we are reminded of our amazing roster of investors. For a timely topic, today we highlight another of our Series..

HZO Investor Profile: Harris & Harris Group

Feb 12, 2015

Today, we highlight one of the earliest private equity investors in HZO, Harris & Harris, a publicly traded company listed on NASDAQ under the ticker symbol TINY. H&H follows a..

HZO Investor Profile: Prudence Holdings

Dec 29, 2014

As 2014 comes to a close, we want to introduce another of our investors, Prudence Holdings, a founding investor in HZO. You may not have heard of Prudence, as this New York-based..

HZO Investor Profile: Iron Gate Capital

Sep 25, 2014

What do an e-commerce company that serves emerging apparel brands (Branded Online), a post-bill audit and recovery service for large hospitals (AcuStream), an artificial heart..

HZO Success Story: NavELite

Sep 08, 2014

In 2013, Andy Wilson of NavELite faced a tough situation. As a former special forces soldier in the United States Army, Price was familiar with tight spots, but this was..

Hydrophilic vs Hydrophobic: What's The Difference?

Nov 14, 2012

Hydrophilic vs. Hydrophobic Today’s technical terminology can be dizzying. On an average day here at HZO you hear people throw around words like nanotechnology and vapor..

Record-Breaking Sea Kayak Journey Around Ireland

Jun 04, 2012

A few months back, we were contacted with news of an amazing man in Ireland who was going to attempt to break a world record- so we jumped at the chance to do our part in..

Conformal Coating Removal - How to Get Started W/Reference

October 10, 2024 / by Mallory McGuinness-Hickey posted in Conformal Coatings, Coating Process

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Conformal coatings are polymeric films on printed circuit boards (PCBs) that protect against hazards like moisture, pollution, chemicals, and temperature changes. This layer of material is vital for the longevity and reliability of electronic parts. But sometimes, conformal coating removal or rework is necessary.

There are five primary conformal coating materials: acrylics, epoxies, silicones, urethanes, and Parylene. Each material presents its advantages, limitations, challenges, and application methods. Understanding these details can help operators determine how best to remove each material. This is why we will start with a brief summary of each coating material's properties.

Acrylic (AR) Conformal Coating Properties

Low moisture absorption
Relatively short drying times
Clear protective coating
Good electrical and physical properties
Typically brushed, sprayed, or dipped

Epoxy (ER) Conformal Coating Properties

Very robust
Excellent chemical and abrasion resistance
Very rigid conformal coating
High dielectric strength
Typically brushed, sprayed, or dipped

Why Does Conformal Coating Need to be Removed?

Incorrect application - this may lead to incomplete coverage, bubbles, or excessive thickness. If these defects hurt the circuit board's function or reliability, operators must remove and reapply the coating.
Need for repairs - during repairs, removal allows for precise soldering and component replacement.
Rework - this often involves altering circuits, necessitating access that is obstructed by existing coatings.
Failure analysis - failure analysis can prevent future errors. But, technicians must examine the original circuit materials without obstruction.

Read the definitive paper on electronic protection methods

Before Removing Conformal Coatings - Safety Precautions

Safety is paramount before removing conformal coatings from electronic components. The compounds and methods for stripping conformal coatings can be risky. If proper precautions are not followed, they can harm health.

Essential Safety Measures

Dedicated working environments with adequate ventilation are required. This is non-negotiable. Solvent fumes can be harmful if inhaled in high concentrations. So, a well-ventilated area, using natural means or fume extractors, minimizes inhalation risks. Also, some coating removal techniques create dust or aerosols. So, use suitable air filtration systems.

Flammability is another factor to consider. Several solvents and chemicals employed in the removal processes are highly flammable. To prevent combustion, keep the workspace free of ignition sources, like sparks or open flames.

Electricity poses a significant risk. Turn off and unplug all devices. This will prevent accidents during the conformal coating removal process.

How to Remove Conformal Coating - First Step

Check the coating on the PCB you want to remove. This will help find the best method to remove the conformal coating. You can usually confirm this by contacting your coating supplier. Or, look for a JEDEC or IPC label on the board. Coatings are designated as AR, SR, ER, UR, or XY, indicating which coating you are working with. If there are no labels, you can still identify the material via methods outlined by the IPC below.
Each conformal coating has distinct properties. So, you can test for transparency, solubility, hardness, thermal removal, and thickness. These tests will show you which type of coating you have. For more information, see IPC’s “Coating Removal, Identification of Conformal Coating” guidelines.

Coating Removal Techniques

After identifying your coating, the next step is to choose the removal technique. Popular methods are briefly discussed below:

Peeling Method

For RTV silicone or thick rubber coatings, use a dull blade or knife to slit and peel off the coating.

Chemical Solvent Method

This process effectively removes urethane, acrylic, and silicone coatings. Prep the area with high-temperature tape and apply solvent using a foam swab.

Grinding and Scraping Method

This removal technique can grind away thin, hard coatings with a micro motor or rotary-style tool or soft coatings with a rotary brush.

Thermal Method

Using low-temperature heat, gently burn and melt the coating material.

Micro Sandblaster Method

This technique involves projecting a fine abrasive powder onto the coating to flake off the material.

Which Technique is Best for My Conformal Coating Material?

Urethane Coatings

Grinding and scraping method
Solvent method
Micro-blasting method

Acrylic Coatings

Thermal removal method
Chemical solvent method
Scraping and grinding method
Micro-blasting method

Epoxy Coatings

Thermal removal method
Grinding and scraping method
Micro-blasting method

Silicone Coatings

Grinding and scraping method
Micro-blasting method
Chemical solvent method
Thermal method

Parylene Coatings

Parylene coatings are often hard to remove. You can usually use micro-blasting, grinding, scraping, and thermal methods. But at HZO, we have simplified the reworking process using technology. The next blog in this series, will discuss reworking Parylene in general and detail how we simplify the process.

For more information on thin-film coatings for your project, contact us today.

Polyurethane Conformal Coatings - Benefits & Applications

October 2, 2024 / by Mallory McGuinness-Hickey posted in Conformal Coatings, Coating Properties

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Conformal coatings are polymeric materials applied to a PCB to improve device reliability. These films protect electronics from environmental threats, including humidity, liquids, and corrosive substances.

Different conformal coating materials include acrylic coatings, silicone, epoxy, and Parylene. Polyurethane is another common conformal coating material.

Learn how to choose the best conformal coating

What is Polyurethane Conformal Coating?

Polyurethane coatings are tough, hard, protective layers that resist solvents and abrasion.

Polyurethane conformal coatings have the following attributes:

Moisture and oil-resistant
Fungicidal
Good flexibility
Can be thinned to achieve a chosen viscosity
Class F temperature rating (160°C/320°F)
Retain excellent electrical insulation properties after the MIL-I-46058 cycling test.

What are the Benefits of Polyurethane Conformal Coating?

Polyurethane can enhance devices. It extends their life and ensures they work reliably in any location.

These coatings exhibit sturdiness and strong resistance to humidity and organic solvents. The tough coatings are resistant to mechanical wear. Additionally, polyurethane can mitigate the growth of tin whiskers.

Polyurethane Conformal Coatings Applications

Polyurethane coatings are ideal in areas with excessive chemical exposure.

Urethane coatings protect and insulate motors, generators, relays, transformers, and other components. This coating material is also common in automotive and aerospace environments. Urethane coatings protect these electronics from chemicals and salt sprays throughout temperature fluctuations.

Learn about protective coatings vs potting

What Do Polyurethane Conformal Coatings Protect Against?

The coatings protect electronics from thermal shock, moisture, chemical solvents, and other elements. Polyurethane has a higher abrasion resistance compared with other materials.

The Polyurethane Conformal Coating Process

Polyurethane comes in single and two-component formulas. You can apply it by dipping, spraying, or brushing. After application, the films are cured to finish the coating. This takes one hour to several days. Single-component urethanes are easy to apply but take up to several days to complete. Meanwhile, two-component formulations cure within hours. The process length is also related to temperature. It cures faster at moderately elevated temperatures. UV curing, heat-catalyzed, and moisture curing are common methods to cross-link urethane polymers.

HZO’s coating process differs because we use vacuum deposition with Parylene coatings. To learn more, watch this video:

View a webinar about designing conformal coatings for reliability

Polyurethane Disadvantages

Curing takes time. It needs a long post-cure time. Moisture affects the cure rate and its properties. The coating can also turn yellow with age.

We compare polyurethane's advantages and disadvantages below:

Polyurethane Conformal Coating Pros and Cons:

Polyurethane Advantages:

Good flexibility, particularly at low temperatures.
Excellent chemical resistance.
Good abrasion resistance.
Can be removed using special products.
Can have high tensile strength depending on formulations

Polyurethane Disadvantages:

Higher water absorption rate than Parylene, acrylics, and silicones.
Difficult to remove.
Curing process can be long.
Low melting point.
Moisture can impact cure rate and cured properties.
Long post-cure time to reach full properties.
Potential to stress components during temperature cycling.
Can yellow with age.

The Big Picture

Choosing a conformal coating requires more than just the material and methods. We must consider several factors. These include the components' complexity, environmental regulations, and coating rework and removal. Repeatable processes that avoid defects may be important, especially for high-reliability applications.

Please read our definitive guide to choose the best conformal coating for your PCB. If you need more help, contact our Applications Engineering team for a consultation. You can also learn more about coatings' protection capabilities.

An Overview of Our Parylene Coating Equipment

September 26, 2024 / by Ryan Moore posted in Parylene, Coating Process

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The development of our coating technology began in 2007. We've come a long way since, filing more than 200 patents and protecting millions of digital devices.

Today, we want to nod to our origin story. We also want to introduce, at a high level, a key material that is a building block of our technology.

Learn more about the Parylene process and Parylene properties.

Parylene Protection

Parylene (or Poly(p-xylylene) as it’s also known) is a protective coating. It's deposited using a chemical vapor deposition process. The material is a moisture-resistant, dielectric thin film barrier. It has been used for over five decades on many corrosion-resistant products. Parylene is biocompatible, has superior barrier properties at 50% thickness and is chemical-resistant. Think big. Think powerful. Parylene has been protecting equipment and products in some of the world's most advanced industries for decades.

Read more about WHY ENGINEERS USE PARYLENE

HZO has developed its proprietary technology using Parylene as a building block. Over the years, it has improved its chemistry and processes. It also automated its Parylene masking and removal equipment. These innovations form a unique and powerful conformal protective solution.

Parylene Overview

So why have most people never heard of it? A major obstacle to wider adoption of Parylene is its high cost. This affects many products, including consumer devices.

Learn more about Parylene coating cost considerations

The Parylene deposition system and its raw material are expensive. There have been challenges with scalability, manufacturing, and device complexity. There has also been a manual process for masking and demasking sensitive areas that need protection from protective layering.

To the credit of Parylene companies that have been in that market for much of this journey, the technology has improved dramatically over time. The material has a sterling reputation in certain markets where development has been focused. But what about other industries that need the same kind of powerful protection?

HZO Parylene Coating Equipment Broadens the Scope

HZO has expanded the use of this powerful, organic material. It has made it available to companies and manufacturers that had not considered it an option until now. The application’s utility is what separates HZO from other companies in the Parylene space.

We talk a lot about the power of the Total HZO Solution. This includes more than our thin-film protective layering technology. That technology protects digital devices from corrosive liquids. It also includes advances in equipment, integration, and specialized processes. These are required to protect some of the world's most complex digital devices. HZO is a leader in custom solutions for digital devices. Years of work on the technology have made it so. Parylene is part of that solution.

Our ongoing innovations benefit every company we work with. HZO has made Parylene's benefits more accessible and affordable than ever. As a result, more sweat and corrosion-resistant products are reaching consumers. The change in performance is starting to get noticed, and the cry for better protection on consumer devices has never been stronger.

Parylene Biocompatibility - Parylene Compared, Analyzed For Medical

September 24, 2024 / by Mallory McGuinness-Hickey posted in Parylene, Coating Properties

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Biocompatibility is vital to medical device safety. It ensures implants and other devices can be used in and on the body with minimal adverse reactions. Medical devices must be highly biocompatible, as they often contact the body's internal tissues and fluids.

Parylene's biocompatibility is crucial for its use in medical devices. Additionally, Parylene is physiologically non-reactive and isn't toxic.

Parylene's Biocompatibility

Medical professionals and device makers rely on strict biocompatibility testing for safety. They follow established standards, especially ISO 10993 and the USP VI Standard.

A complete analysis of Parylene shows it is biocompatible. It meets the strict standards for medical device use. Third-party sources have tested the material, and it causes no harm to tissues or body fluids. Parylene's chemical inertness makes it compatible. It provides a safe interface between the device and human tissue.

Why is Parylene Biocompatible?

Parylene's chemistry and structure make it biocompatible. It meets the USP's highest, Class VI, biocompatibility standards. Parylene has passed the USP's strict tests, described here. Also, it has a proven track record of reliable performance in the medical device industry.

Biocompatible Parylene Coatings Last

Decades of use show Parylene coatings maintain their performance and integrity. Bodily fluids, varying pH levels, and enzymes do not reduce their effectiveness. Parylene-coated medical devices are vital. They provide reliable, long-lasting protection and function.

Parylene's uniform, pinhole-free coating does more than protect. It provides a reliable interface between the device and the body. So, encapsulated medical components can serve patients for as long as they are used. The difference is not just in Parylene's inertness. Parylene can also resist the harsh conditions of the human body.

Below, you can see a Parylene-coated Raspberry Pi computer running underwater in HZO’s lobby. As of the date of publication, this computer has been running fully submerged in tap water for over two years now:

raspberry pi running underwater with HZO Parylene coating

Parylene Versus Other Biocompatible Materials

Parylene often stands out for its unique properties. So, it is a good biocompatible material for medical uses. But, a range of alternatives exists. They include silicone, Teflon, and various medical-grade metals and polymers. Each material has a unique set of traits best in certain conditions.

Parylene is known for its great chemical resistance. It can also form pinhole-free coatings at a micron-level thickness. This lets devices work reliably in the harsh human body. Parylene coatings are ultrathin. They keep the feel and function of the underlying material. This is a big advantage over bulkier options like silicone rubber or polyurethane.

Parylene vs. Stainless Steel

Consider Parylene versus stainless steel, which is a common choice for implants. Stainless steel is strong and fatigue-resistant. But it can't match Parylene's ability to conform to complex shapes. The difference shows in applications needing a seamless coat over complex parts. Here, Parylene's conformal nature gives a uniform layer. It fully isolates the parts from the body's fluids and tissues.

Parylene vs. Teflon

Unlike Teflon, a popular biocompatible material, Parylene is PFAS-free. It is REACH and RoHS compliant, and its ability to maintain physical integrity under sterilization methods boosts its comparability.

The Limitations of Biocompatible Parylene

However, Parylene is not without its limitations. Parylene has great barrier properties and electrical insulation. But, its mechanical strength is not as good as that of metals or ceramics. This property requires careful thought in load-bearing implant uses where strength is vital. Also, the Parylene application process uses chemical vapor deposition. It's very effective but may complicate the manufacturing workflow. Simpler methods, like dip or spray coating, are used for silicone and latex.

Read about how to incorporate Parylene into your process

Other materials may have specific advantages, like higher tensile strength or elasticity. But, Parylene's combination of properties often justifies its selection. It depends on the intended use, performance, and regulatory standards. Manufacturers must balance performance and material costs. They also consider the complexity of application methods for producing and using medical devices.

Learn more in our webinar, Parylene: Pros, Cons, and Practicalities

Why is Parylene Used in Medical Applications?

Parylene is a very popular protective coating in the medical industry. In 2023, the parylene market was valued at $98.38 million; by 2030, it is expected to grow to $118.52 million. Why is Parylene so widely used? The answer lies in its powerful protective properties.

Parylene is highly resistant to moisture, chemicals, and other environmental factors. The coatings protect medical devices in and on the body at 50% of the thickness of conventional conformal coatings, reducing product bulk and weight. Also, Parylene has very high dielectric strength, up to 7,000 V/mil. This ensures that electrical components can function uninterrupted by external stimuli.

Parylene's conformal coating attributes ensure a uniform, pinhole-free application. It adheres to every contour of the complex geometries in medical devices. This ensures complete encapsulation with no areas left vulnerable. Parylene's coating uniformity greatly improves device protection.

Download datasheet

Chemical Resistance: Parylene surpasses many materials in its resistance to corrosive bodily fluids.
Dielectric Strength: Parylene N has an extremely high dielectric strength of 7,000 V/mil
Biocompatibility: Parylene causes minimal tissue reaction. It compares well to common biocompatible materials.
Barrier Protection: Parylene's seamless coatings provide unmatched barrier protection. Porous materials, like silicone foams, cannot match it.

Common Uses for Parylene in Medical Settings

Parylene coatings have established their utility in a wide range of medical devices. They improve protection and longevity. Here are some use cases for Parylene:

Cardiac assist devices use Parylene. Its thin, uniform coating reduces thrombogenicity without harming the device's inherent functionality.
Parylene-coated needles and cannulas have less friction. This makes them easier to insert, which is more comfortable for patients.
Parylene coatings improve stents. They prevent corrosion and reduce friction, aiding in their insertion and long-term performance in the body.

Diverse biomedical applications capitalize on Parylene's biocompatibility. It is present in both in vivo and in vitro environments. These include surgical instruments, cochlear implants, and diagnostic equipment sensors.

Partner with HZO for Your Next Medical Project

Do you have any questions about Parylene or what it can do for your next project? Please reach out to our team. We’re standing by to answer your questions and help you determine your next step.

HZO team ready to help you

Parylene Coating Removal - Methods & Best Practices for Each

September 12, 2024 / by Mallory McGuinness-Hickey posted in Parylene, Coating Process

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Parylene coatings present unique challenges when it comes to rework and removal. They often outperform other conformal coatings. Parylene has better barrier properties, uniform coverage, and performance in thinner layers.

Learn more about what Parylene is used for.

Additionally, Parylene's chemical resistance can withstand corrosive gases and liquids. It also performs in extreme temperatures and high electrical activity.

Want to know if HZO Parylene meets your specifications?

Download Datasheet

But, the properties that make Parylene the "gold standard" of conformal coating can also make it hard to remove. Thankfully, you can use methods to remove and rework Parylene when needed.

When Do You Need to Remove Parylene?

From time to time, it is necessary to rework or remove coating. Sometimes, job specifications change or a Parylene vendor incorrectly applies the coating.

What is Parylene Delamination?

One example of poor application is Parylene delamination. This is when the conformal coating separates from the coated surface. This results in an unattached, torn, non-conformal coating and an unacceptable finish. Delamination defeats the purpose of Parylene coatings. It must be avoided at all costs. Even partial lifting can render the protective coating useless.

What Causes Parylene Delamination?

Many causes of Parylene delamination exist. One is demasking, a standard process. It creates a need for high-quality inspections after production. Other causes include:

Coating porosity: A vapor pressure difference creates a risk of moisture intrusion into the substrate. Pressure fluctuations and temperature changes create osmotic pressures. These separate the coating from the component.

Incompatible materials: The Parylene coating must bond with the component surface for successful coverage. When the Parylene and the surface are incompatible, they create incongruous surface energies. This causes minimal bonding.

Contaminated surfaces: Improperly cleaned component surfaces do not support adhesion.

Regardless of the reason, the resulting Parylene removal must be efficient and safe. It must protect the coated substrate's integrity.

The following methods are popular ways to approach Parylene removal.

How Do You Do Mechanical Parylene Removal?

Parylene's strength and uniformity make it tough to remove. So, be careful with mechanical methods. They may damage the final product. However, Parylene is a soft polymer. So, mechanical methods may remove it.

Methods like picking, cutting, and scraping are effective. But, they may damage components, substrates, and delicate track lines. This type of removal requires considerable attention and care. Good spot removal is possible with proper masking. But, mechanical methods may be unreliable for larger surfaces.

How to Remove Parylene with Micro-Abrasion

Micro-abrasion is a process performed with automated or handheld systems. It targets a specific area by blasting the Parylene coating with inert gas or dry air and abrasive media. This removal method is suitable for both whole board and spot removal. It is generally easy to put in place, quick, cost-effective, and environmentally friendly.

Can You Use Thermal Removal With Parylene?

Parylene can withstand high temperatures. But, a high-temperature oven or soldering iron can remove it in small, specific areas. As heat is applied, the coated component rises from the board and lifts off.

This technique may be adequate for small repairs. It is less reliable for large surfaces. But, it can still be effective for some jobs. However, residues and discoloration may occur. Parylene's high melting point may damage heat-sensitive substrates. Thermal removal can be hard to manage. It's not recommended without Parylene experts' help.

thermal removal parylene removal method

Which Chemical Can Remove Parylene?

Parylene is chemically inert, resisting chemical degradation. But, one chemical has been used to strip Parylene from substrates and components. It is a colorless organic compound, tetrahydrofuran (THF), with the formula (CH2)4O. This solvent softens the Parylene coating. It temporarily loosens the bond between the substrate and the coating. At this point, the Parylene can be lifted off with tweezers. THF can remove Parylene, but it may damage the coated part. Use the solvent only for complete coating removal. For the security of the components under the coating, consider other removal methods before using TFH.

Laser Ablation for Parylene Removal

Laser ablation is a process that removes material from a surface by irradiating it with a laser beam. The beam can cut, drill, or mark delicate materials, providing precise removal. At HZO, a laser ablation process converts Parylene to gas or plasma with pulsed laser sources. This method is cost-effective for complex removals. It gives better results. It can also service 3D devices and Parylene-free areas.

Conclusion

There are many effective methods to remove Parylene should the need arise. Each method has its strengths. So, you must know your options. Then, choose the best method for your project.

If you need Parylene removal or want to discuss your project with experts, please message us today. Removing Parylene can be tough. But, a skilled company can simplify and lower the cost of the job. We can help with scalable Parylene equipment and Parylene masking automation. We can also address concerns about the cost of Parylene services.

MIL-I-46058C: Definitive Guide to Military Standards for PCBAs

August 6, 2024 / by Mallory McGuinness-Hickey posted in Protection Capabilities

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Reliability is a top priority in defense and aerospace electronics in harsh, unforgiving environments. The MIL-I-46058C standard is a guideline for conformal coating materials that helps keep PCBAs safe from military environments, ensuring dependable performance. Although IPC-CC-830 replaced this standard in 1998, understanding MIL-I-46058C is still non-negotiable for industry compliance and mission success.

Even though deemed inactive for new designs since 1998, MIL-I-46058C remains an independent standard for companies who supply conformal coatings for two essential reasons: it is the only published standard that includes a qualified product list used by the DOD, and the standard also requires certification by an independent third party.

The criteria set forth by MIL-I-46058C for conformal coatings are integral in aerospace and defense applications. These coatings must withstand extreme atmospheric conditions, rapid pressure changes, and varying degrees of moisture and chemical exposure. Adherence to such standards ensures operational effectiveness and safety in critical missions.

Importance of MIL-I-46058C

In the realm of military specifications and standards, MIL-I-46058C stands out for its stringent criteria for conformal coatings. It represents a level of assurance for military equipment that non-military standards do not necessarily guarantee. By complying with this specification, manufacturers and defense contractors can affirm the longevity and performance of their electronic components, even in the harshest environments, by using the proper coating materials.

The primary function of conformal coatings is protection: they are a barrier that prevents contamination, such as chemicals, moisture, and humidity, from causing short circuits or corrosion.

Coatings such as acrylics, urethanes, epoxies, silicones, and Parylene also resist corrosive gases and salt sprays, reduce mechanical stress due to handling or thermal expansion, and protect against corrosive gases and salt sprays.

Military Standards for Humidity and Environmental Protection

MIL-I-46058C establishes clear humidity and environmental protection requirements. Ensuring electronics meet such standards is essential for performance and longevity, especially in military and aerospace applications where failure is not an option.

Electrical Insulating Properties

Conformal coatings possess significant electrical insulating properties essential to preventing electrical leakage and ensuring the current flows only where it is meant to go. This characteristic is particularly valuable in high-density circuitry where electrical components are closely packed, reducing the risk of interference or shorts between conductors.

Coatings under the MIL-I-46058C specification are designed to act as electrical insulators, creating a dielectric layer that safeguards circuitry from shorts and arcing caused by environmental challenges.

Their resistance to electricity contributes significantly to preventing malfunctions and potential damage. With an appropriate application, conformal coatings provide excellent insulation, even under fluctuating electrical loads.

Defining Thermal and Mechanical Standards

The MIL-i-46058C specification is instrumental in defining the thermal and mechanical performance parameters for conformal coatings used in military and aerospace applications. It ensures that coatings are capable of functioning under stringent conditions without degrading performance, encompassing:

Tensile Strength: The coating's ability to withstand pulling forces without breaking
Thermal Shock Resistance: The coating's capacity to endure sudden changes in temperature without compromising its structural integrity
Flexibility: The ability of the coating to flex with the substrate material, which is essential for performance during mechanical or thermal stress

Mastering Application Techniques for MIL-I-46058C Conformal Coatings

Whichever application process (dipping, spraying, vacuum deposition, brushing) is used, achieving uniform coating and coverage is the primary concern. Factors such as temperature, humidity, and the geometry of the printed circuit board (PCB) can all influence the outcome. It's essential to follow strict processing guidelines, provide adequate training for operators, and implement inspection procedures to ensure that the conformal coatings delivered meet the high standards set by MIL-I-46058C.

Quality Control, Testing, and Industry Compliance

In the realm of conformal coatings and electronic circuit protection, Quality Control (QC) and rigorous testing are pivotal in ensuring that products meet the stringent requirements of MIL-I-46058C. For manufacturers and service providers in the electronics industry, adherence to recognized standards is a benchmark for quality and a requirement for credibility and trustworthiness in the marketplace.

It's essential to have a well-established process encompassing multiple tests and inspections to comply with the MIL-I-46058C specification. This involves:

Thorough examination of thickness uniformity and coverage using various measurement techniques
Stringent electrical testing to ensure that the conformal coating does not impede the intended function of the PCB
Mechanical and environmental stress testing to verify that the coating can withstand harsh conditions without degrading

Quality control in the application of conformal coatings is multi-faceted, including:

Visual inspections for surface defects post-application
Adherence to production protocols that minimize the risk of contamination
Product batch testing to ensure consistent quality across different manufacturing lots

These QC procedures are integral to maintaining the high standards expected in industries where reliability is paramount.

Read About HZO's Coating Process

Processes for Ensuring Compliance with MIL-I-46058C

Coatings optimized for the MIL-I-46058C specification must undergo tests to affirm that the PCBs meet the rigorous demands of their respective applications. The MIL-I-46058C specification outlines a series of stringent tests to evaluate the corrosion resistance of conformal coatings.

High humidity exposure, salt fog conditions, and immersion trials are methods used to simulate extreme environments and validate a coating's protective capabilities. Adherence to these testing protocols is crucial for manufacturers to certify that their conformal coatings meet the high standards expected for components in critical applications.

Humidity Exposure: Coatings are tested for their ability to withstand high moisture levels without degrading.
Salt Fog/Spray Testing: Assesses the coating's resistance to corrosive salt environments mimicking marine conditions.
Immersion Trials: Ensures that coatings can protect components even when submerged in liquids.

Through rigorous testing and compliance with MIL-I-46058C, electronics manufacturers can ensure that their products stand up against environmental challenges, thereby reducing maintenance costs and extending the operational lifespan of the devices they protect.

See HZO nanocoatings pass in-house testing

Industry Certifications and Compliance

While the MIL-I-46058C provides a comprehensive framework, aligning with broader industry certifications reinforces a commitment to excellence. Relevant certifications might include:

ISO 9001: For quality management systems
IPC-A-610: For acceptability of electronic assemblies
IPC-CC-830B: For electronic circuit protection conformity

Sustaining such certifications ensures that a company's products are compliant with military specifications and meet high-quality standards recognized internationally within the electronics sector.

Differences between MIL-I-46058C and other standards like IPC-CC-830

MIL-I-46058C specifies testing methods and minimum performance requirements, focusing on the suitability for military environments. Meanwhile, IPC-CC-830 is typically utilized within the civilian sector and offers broader guidelines for conformal coating use.

While both set high standards for protecting electronics, MIL-I-46058C is tailored for military applications that often face more extreme operational scenarios.

Understanding the nuances between MIL-I-46058C and standards like IPC-CC-830 is crucial for those supplying electronics to military and commercial markets. Selecting an appropriate conformal coating that adheres to relevant standards is a critical factor that drives the long-term success and dependability of sensitive electronic equipment.

Addressing Obsolescence: Alternatives

As technology evolves, so do the standards that govern it. With MIL-I-46058C now considered obsolete, manufacturers may wonder how to navigate this change effectively. The discontinuation of this military standard has prompted the electronics industry to seek modern alternatives that provide equivalent or superior protection for electronic components.

Manufacturers must comprehend this obsolescence and its implications for production and quality assurance processes. A proactive approach is necessary to adapt to new regulations and maintain compliance.

One of the prominent specifications that have emerged as a successor to MIL-I-46058C is IPC-CC-830. This standard is widely recognized in the industry and is designed to meet the current and future demands of electronic device protection. Manufacturers can confidently transition to IPC-CC-830, knowing it offers a comprehensive framework for ensuring the reliability and longevity of their products.

Tips for Transitioning to New Standards

Moving to contemporary specifications like IPC-CC-830 can be a daunting task. Below are some essential tips to facilitate a smooth transition:

Conduct a thorough analysis of current processes and how they align with new standards.
Engage with material suppliers to identify conformal coatings that meet the requirements of IPC-CC-830.
Schedule training for the production and quality assurance teams on the nuances of the new standard.
Implement a phased approach to transition, allowing ample time for adjustments and validation.
Consider consulting with industry experts who can offer insights and guidance on maintaining compliance.

By embracing these modern specifications, manufacturers not only comply with the current standards but also position themselves to adapt more readily to future advancements in technology and regulatory environments.

MIl-I-46058C Coatings With HZO

HZO coatings have passed IPC-CC-830 (widely considered an active alternative to MIL-I-46058C) at 50% of the thickness of conventional coatings, providing the protection required for military applications at a fraction of the mass. HZO is ITAR-registered and ready to partner with you on your military application. Contact one of our engineers to learn more. Stay informed, stay compliant, and, most importantly, remain confident in the quality of your military and aerospace applications.

Polymer Glass Transition Temperature - Material Properties, Impact

September 21, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Polymer glass transition temperature (Tg) refers to the temperature at which an amorphous polymer transitions from a glassy, rigid state to a rubbery, flexible state. Understanding the polymer glass transition temperature is crucial for various industries, including engineering and manufacturing. The Tg provides valuable insights into a polymer's behavior, such as its processing, mechanical, thermal, and overall performance characteristics.

The polymer's structure, molecular weight, chemical composition, and branching influence the glass transition temperature. The Tg affects properties like stiffness, impact resistance, thermal stability, and transparency. Design engineers can optimize material selection, processing conditions, and performance requirements by understanding how the Tg relates to polymer structure.

Basics of Glass Transition

The glass transition is a phenomenon that occurs in amorphous polymers where the material changes from a rigid and brittle state to a softer and more flexible state when certain temperature conditions are met.

Several factors can affect the glass transition temperature (Tg) of polymers:

Molecular weight and chain length: Polymers with higher molecular weights and longer chain lengths tend to have higher Tg values.
Chemical structure and composition: Different chemical structures and compositions can result in variations in Tg values.
Presence of plasticizers or additives: Plasticizers and additives can lower the Tg of polymers, making them more flexible and less brittle.
Crystallinity or amorphous nature of the polymer: Amorphous polymers generally have lower Tg values than crystalline polymers.

Influence of Glass Transition Temperature on Polymer Properties

A polymer's glass transition temperature (Tg) plays a crucial role in determining its properties and performance. This temperature marks the transition from the glassy state to the rubbery state, where the polymer undergoes significant changes in its physical and mechanical behavior.

Impact on mechanical properties

The glass transition temperature has a profound effect on various mechanical properties of polymers, such as:

Tensile strength: The Tg of a polymer can influence its tensile strength. Polymers with a higher Tg tend to have higher tensile strength, as the increased molecular mobility at elevated temperatures allows for better alignment and bonding.
Elastic modulus: The Tg also affects the elastic modulus, which refers to a material's ability to resist deformation. Polymers with a higher Tg typically exhibit a higher elastic modulus, indicating greater stiffness and rigidity.
Impact resistance: The Tg can impact the impact resistance of polymers. As the Tg increases, the polymer becomes more brittle and prone to fracture upon impact. On the other hand, polymers with lower Tg values exhibit better impact resistance and toughness.

Effect on thermal behavior

The glass transition temperature has significant implications for the thermal behavior of polymers:

Melting temperature and thermal conductivity: The Tg influences the melting temperature of a polymer. Polymers with higher Tg values generally have higher melting temperatures. Additionally, a higher Tg can result in lower thermal conductivity, which affects the material's ability to transfer heat.
Heat resistance and aging: The Tg indicates a polymer's heat resistance. Polymers with high Tg values exhibit better heat resistance and are less prone to degradation at elevated temperatures. Furthermore, understanding the Tg is crucial for predicting the long-term aging behavior of a polymer in various environmental conditions.

Temperature-Dependent Polymer Properties

Temperature plays a crucial role in determining the properties of polymers. As the temperature changes, various characteristics of polymers undergo significant transformations. Understanding the temperature-dependent behavior of polymers is essential for a wide range of applications, from material selection to manufacturing processes.

Changes in Polymer Properties with Temperature Variations

When exposed to different temperatures, polymers exhibit distinct alterations in their properties. These variations include changes in mechanical strength, electrical conductivity, chemical resistance, and dimensional stability. For example, as the temperature rises, the mechanical strength of a polymer tends to decrease due to increased molecular motion.

Relationship Between Glass Transition Temperature and Other Temperature-Dependent Properties

Glass transition temperature has a relationship with other temperature-dependent properties, including:

Specific heat capacity: The glass transition temperature of a polymer is closely related to its specific heat capacity, which is the amount of heat required to raise the temperature of a unit mass of the material by a certain degree. Understanding this relationship is essential for predicting polymers' heat absorption and release capabilities at different temperatures.
Coefficient of thermal expansion: The coefficient of thermal expansion measures the extent to which a material expands or contracts when subjected to temperature changes. The glass transition temperature considerably influences the coefficient of thermal expansion of polymers. Higher glass transition temperatures generally result in lower coefficients, indicating reduced dimensional change with temperature.
Viscosity and flow behavior: As the temperature varies, polymers experience viscosity and flow behavior changes. Polymers act as rigid solids with high viscosity at temperatures below the glass transition temperature. However, as the temperature surpasses the glass transition temperature, polymers transition into a more flexible state, exhibiting lower viscosity and increased flow characteristics.

Measurement and Determination of Values

Obtaining accurate glass transition temperature data is essential. Several experimental techniques may be employed for measurement, including:

Differential Scanning Calorimetry (DSC): DSC is a widely used technique that measures the heat transfer in a sample as it goes through a glass transition. It provides information about the glass transition temperature and the enthalpy of transition.
Dynamic Mechanical Analysis (DMA): DMA measures the mechanical properties of a sample as a function of temperature or frequency. It can provide information about the glass transition temperature by observing changes in the sample's modulus, damping, and storage modulus.
Thermomechanical Analysis (TMA): TMA measures the dimensional changes of a sample as a function of temperature or time. It can determine the glass transition temperature by monitoring changes in the sample's dimensions.
Fourier Transform Infrared Spectroscopy (FTIR): FTIR measures a sample's absorption of infrared light. Analyzing the changes in the infrared spectra of the sample as a function of temperature can determine the glass transition temperature.

Factors influencing the accuracy and repeatability of glass transition temperature measurements

Several factors influence the accuracy and repeatability of glass transition temperature measurements, such as:

Heating and cooling rates: The rate at which the sample is heated or cooled can affect the observed glass transition temperature. Different heating and cooling rates can lead to variations in the measured value.
Sample preparation and handling: How the sample is prepared and handled before the measurement can also impact the glass transition temperature. Contamination or improper handling can introduce errors.
Physical state of the polymer (solid, liquid, or semi-solid): The physical state of the polymer can affect the glass transition temperature measurement. Different states can exhibit different glass transition temperatures.
Presence of impurities or additives: Impurities or additives present in the polymer can influence the observed glass transition temperature. These substances can alter the polymer's molecular structure and affect its behavior during the glass transition.

Role in material applications

The glass transition temperature influences the choice of polymers in various industries and applications, including:

Automotive and aerospace: The Tg of polymers used in automotive and aerospace applications is critical, as it determines their ability to withstand high-temperature environments and maintain dimensional stability.
Consumer goods and electronics: The Tg influences the selection of polymers for consumer goods and electronic devices. Polymers with suitable Tg values are chosen to ensure durability, impact resistance, and resistance to heat and aging.
Medical and healthcare sector: The Tg of polymers used in medical and healthcare applications is essential for ensuring biocompatibility, sterilizability, and resistance to various environmental factors.

This diverse range of applications highlights the glass transition temperature's crucial role in tailoring polymer properties to meet specific requirements. Contact our engineers if you need to choose a protective coating material with a particular glass transition temperature and require assistance or learn more about thin film protection capabilities, such as coefficient of linear expansion, thermal conductivity, or optical properties, such as refractive index or transparency.

What is Coefficient of Linear Expansion? Formula, Units & More

September 21, 2023 / by Mallory McGuinness-Hickey posted in Coating Properties, Thin Film Applications

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Temperature affects the behavior of materials, causing them to expand or contract. However, not all materials respond to temperature variations in the same way. Some materials, like metals, tend to expand when heated, while others, like water, show a more complex behavior, with expansion occurring at specific temperatures.

Learn about other thermal coating properties, like thermal conductivity and glass transition temperature.

This property is crucial in predicting how a material will respond to temperature changes. This coefficient, represented by the Greek letter alpha (α), describes how much a material expands per unit length for each degree of temperature rise. Understanding this concept helps engineers make accurate predictions and design structures that can withstand temperature fluctuations.

Formula for Calculating the Coefficient of Linear Expansion

The coefficient of linear expansion (α) can be calculated using the following formula:

α = ΔL / (L₀ × ΔT)

Where:

α is the coefficient of linear expansion

ΔL is the change in length

L₀ is the original length

ΔT is the change in temperature

Units used for expressing the coefficient

The coefficient of linear expansion is typically expressed in units of length per unit temperature, such as millimeters per degree Celsius (mm/°C) or inches per Fahrenheit (in/°F). These units emphasize the linear dimensions and temperature change required to induce a specific change in length. By using consistent units, scientists and engineers can easily compare and analyze the behavior of different materials.

Measurement and Units

Accurately measuring values is essential in understanding how materials respond to changes in temperature. Several experimental techniques are commonly employed to measure the coefficient of linear expansion. The most widely used method is known as the thermal expansion apparatus. This apparatus consists of a rod or sample material, which is heated or cooled while its length changes are recorded. By carefully analyzing the recorded data, researchers can calculate the coefficient of linear expansion for the material.

The interferometric method utilizes interference patterns created by light passing through a material. This technique accurately measures the changes in length resulting from thermal expansion.

Additionally, some advanced techniques like dilatometry, which involves measuring volume changes, and strain gauges, which record dimensional changes, are used for highly precise measurements of the coefficient of linear expansion.

Relationship between the Coefficient of Linear Expansion and Thermal Expansion

Thermal expansion refers to the increase in size or volume of a material as its temperature rises. This expansion occurs because heat causes the atoms and molecules within the material to move more rapidly, increasing their average spacing. As a result, the material takes up more space and expands.

Meanwhile, the coefficient of linear expansion represents the change in length per unit length per unit change in temperature.

The relationship between the coefficient of linear expansion (α) and thermal expansion can be expressed using the following formula:

Thermal expansion = coefficient of linear expansion × Original length × Change in temperature

This formula allows engineers to calculate a material's dimensions change when its temperature changes.

Factors Influencing the Coefficient

Several factors can influence the coefficient of linear expansion in materials. These factors can affect how much a material expands or contracts when subjected to changes in temperature.

Crystal Structure, Bonding Types, and Impurities

The crystal structure of a material heavily influences the coefficient of linear expansion. Different crystal structures can lead to variations in the coefficient. The type of bonding between atoms in a material can also affect its coefficient. For example, materials with stronger intermolecular forces tend to have lower coefficients, while those with weaker ones tend to have higher ones.

Impurities in a material can also impact its coefficient of linear expansion. Their presence can disrupt the regular arrangement of atoms, causing changes in the expansion behavior.

External Factors

External factors such as pressure, magnetic fields, and electric fields can also influence this value. Pressure can alter the arrangement of atoms in a material, affecting its expansion behavior. Similarly, magnetic fields and electric fields can cause changes in the alignment and movement of atoms, leading to variations in the coefficient.

Material Selection

This property is highly dependent on the material properties of a substance. Different materials exhibit different coefficients due to their unique structures and bonding arrangements. For example, materials with stronger intermolecular forces tend to have lower values because their particles are held tightly together, making them less likely to expand significantly with temperature changes.

Material properties such as elasticity, rigidity, and thermal conductivity also play a significant role in determining this value. Elastic materials can return to their original shape after being subjected to deformation caused by thermal expansion. On the other hand, rigid materials are less prone to significant expansion due to their stiffness and resistance to deformation.

Additionally, materials with high thermal conductivity tend to have higher values. High thermal conductivity allows for faster heat transfer, leading to greater expansion or contraction in response to temperature changes.

When dimensional stability is critical, materials with low coefficients are preferred to minimize undesired expansions or contractions. On the other hand, materials with higher coefficients may be utilized in applications where controlled expansion is desired.

Engineers can make informed decisions regarding material selection, product design, and manufacturing processes by understanding how different materials expand or contract with temperature changes. This knowledge helps create efficient and durable structures, products, and systems. If you are looking for a coating material to suit your application needs, please contact our engineers to discuss DFM. Or, learn more about thin film protection capabilities, such as optical properties like transparency and index of refraction.

What is Thermal Conductivity? Explanation, Measurement, Uses

September 21, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Thermal conductivity is a fundamental concept in heat transfer and is crucial in multiple industries and scientific disciplines. It refers to the ability of a material to conduct heat or the rate at which heat transfers through a substance. Understanding this property is essential for designing efficient thermal systems, optimizing energy usage, and ensuring the safety and performance of various materials and products.

Learn about other thermal coating properties like glass transition temperature and linear coefficient of expansion

Understanding heat and its relationship to thermal conductivity is essential in grasping the concepts of heat transfer. Heat, in its simplest form, transfers energy from one object to another due to temperature differences.

Temperature gradient plays a significant role. A temperature gradient refers to the difference in temperature between two points in a material or between two adjacent materials. Heat transfer occurs when there is a temperature gradient, with heat flowing from regions of higher temperature to regions of lower temperature.

This phenomenon is driven by the basic principle of nature - the tendency of a system to seek equilibrium. When there is a temperature difference, the system will naturally attempt to balance the temperatures, leading to heat transfer and thermal conductivity.

The Physics Behind Thermal Conductivity

Thermal conductivity is a fascinating concept deeply rooted in the fundamental principles of physics. At its core, thermal conductivity is defined as the ability of a material to conduct heat. This ability is determined by various physical factors that govern the flow of heat energy.

The mechanisms of heat conduction can explain this property at the molecular level. Heat conduction occurs when a temperature is different between two points in a material. In simple terms, it is the movement of heat energy from higher-temperature to lower-temperature regions.

One of the fundamental relayed principles is the concept of thermal resistivity. This refers to a material's resistance to the flow of heat. Materials with lower thermal resistivity have higher thermal conductivity, allowing heat to be transferred more easily.

Another essential principle is the role of atomic and molecular interactions. Heat energy is transferred through these interactions as atoms or molecules collide and exchange kinetic energy. A material's structure and arrangement of atoms or molecules can greatly impact its values.

Measurement Techniques

Measurement techniques are crucial in providing accurate data to understand thermal conductivity. Various experimental methods have been developed to measure thermal conductivity, each with advantages and limitations.

Overview of Experimental Methods

Experimental methods for measuring involve subjecting the material to controlled thermal conditions and observing the resulting heat transfer. These methods can be broadly classified into steady-state and transient techniques.

Steady-State Heat Flow: This method involves establishing a steady-state heat flux through the material and measuring the temperature gradient. Knowing the sample's dimensions and the temperature difference, the value can be calculated using Fourier's Law of heat conduction.
Transient Hot Wire Method: A thin wire with a known value is placed in contact with the material in this technique. A constant heat flux is applied to the wire, and the temperature rise is measured. By analyzing the rate of temperature change, thermal conductivity can be determined.
Laser Flash Analysis: Laser flash analysis is commonly used to measure thermal conductivity in solids. This method applies a short pulse of laser light to one end of the sample, creating an instantaneous temperature rise. The temperature decay is then measured and analyzed to calculate the value.

Non-Destructive Testing Techniques

Non-destructive testing techniques are commonly employed when measurements must be taken on finished products or structures without altering their integrity. These methods offer convenience and allow for thermal conductivity measurements in real-world applications.

Some non-destructive testing techniques commonly used for measuring thermal conductivity include infrared thermography, ultrasound, and thermal wave analysis. These techniques utilize the principles of heat transfer and allow for non-intrusive measurement of thermal conductivity in various materials.

Applications of Thermal Conductivity

The concept of thermal conductivity is essential in designing and optimizing thermal insulation materials to reduce heat loss or gain. It is also pivotal in developing efficient heat exchangers, such as those used in HVAC systems, refrigeration units, and power plants.

Additionally, it is a key factor in determining the performance and efficiency of electronic devices, such as computer processors and power electronics. Optimizing this value helps dissipate heat generated by these devices, preventing overheating and ensuring longevity.

Here are some examples of the wide-ranging applications of thermal conductivity:

Designing heat sinks for electronic devices: This property helps dissipate heat generated by components, ensuring optimal performance and preventing overheating.
Energy recovery systems: Energy recovery systems aim to capture and utilize waste heat generated by industrial processes. By efficiently transferring heat, it enables the conversion of waste heat into usable energy, reducing energy consumption and costs.
Enhancing thermal management in engineering applications: The property helps design and optimize cooling systems, ensuring efficient heat dissipation and preventing equipment failure due to overheating.

Due to the importance of this material property, selecting a protective coating material with the most suitable value is paramount. Please get in touch with us if you are a design engineer and have questions about protective coatings for electronic components. Otherwise, learn more about protective coating protection properties, such as optical properties like refractive index and transparency.

What is the Index of Refraction? Measurement, Definition & More

September 20, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Understanding how light travels through different mediums is essential in optics. One invaluable optical property is the index of refraction. This measurement quantifies how much a ray of light bends when it passes from one medium to another. The index of refraction plays a crucial role in understanding the behavior of light in various optical devices and phenomena.

Read more about transparent polymers.

Definition of the Index of Refraction

The index of refraction is a numerical value that represents the ratio between the speed of light in a vacuum and the speed of light in a given material. It determines how much the direction of light changes as it passes through a medium, such as air, water, or glass.

The higher the value, the slower light travels through the material, resulting in a greater bending or refraction of the light ray. This is due to the interaction between the electromagnetic waves of light and the charged particles within the medium.

Measurement Methods

Several methods exist to accurately measure the index of refraction. Here are some widely used techniques:

Using refractometers: Refractometers are optical devices that determine the index of refraction by measuring the angle at which a light ray bends when passing through a sample material.
Employing mathematical models based on the speed of light: This involves calculations using mathematical equations that incorporate the speed of light in a vacuum and the speed of light in a particular medium. These models consider variables such as wavelength and frequency to derive the index value accurately.
Snell's Law: Snell's Law is a fundamental principle that relates the angles of incidence and refraction between two mediums. By measuring these angles and applying Snell's Law, the index of refraction can be determined.
Speed of Light: Another way to measure the index of refraction is by comparing the speed of light in a vacuum to the speed of light in a particular medium. This method requires precise measurements of the speed of light and the refractive properties of the medium.
Critical Angle: When light travels from a medium with a higher refractive index to a medium with a lower refractive index, it can reach a critical angle at which total internal reflection occurs. By measuring this critical angle, the index of refraction can be determined.
Dispersion: Dispersion refers to the phenomenon where different wavelengths of light (colors) refract at different angles when passing through a medium. By studying the dispersion of light, scientists can derive the index of refraction for each wavelength, creating a refractive index spectrum.

These measurement techniques allow engineers to understand better how light interacts with matter.

Refractive Index and the Speed of Light

Light, as we know, travels at an incredible speed through space. However, when it enters a medium, such as glass or water, its speed is significantly reduced due to the phenomenon of the index of refraction. Understanding the relationship between the index of refraction and the speed of light is crucial in various scientific and practical applications.

Why light travels slower in mediums with higher refractive indices:

When light passes through a medium, it interacts with the atoms and molecules in that medium. These particles cause the light to slow down as it continuously gets absorbed and re-emitted. The higher the refractive index of the medium, the more significant this effect becomes, resulting in slower light propagation.

Effects of different materials on the speed of light propagation:

Materials with higher refractive indices, such as diamond or glass, slow down light considerably. In contrast, materials with lower refractive indices, such as air or vacuum, allow light to travel at its maximum speed. This variance in speed is why light bends or changes direction when passing from one medium to another.

Index of Refraction and Product Design

The index of refraction has numerous practical applications in various fields. One application is the design of optical fibers, lenses, microscopes, telescopes, and other devices. By manipulating the path of light through different materials with different refractive indices, engineers can achieve desired outcomes such as focusing, magnification, and dispersion.

Additionally, understanding the behavior of light as it interacts with different materials allows engineers to develop and improve optical instruments. These instruments, ranging from cameras to spectrometers, rely on the principles of the index of refraction to function effectively.

If you are working on an application that requires a protective coating with certain optical properties, HZO might be able to help. Please contact us to speak to an engineer. Or, if you are more interested in learning about protective coating capabilities, read about thermal conductivity, linear coefficient of expansion, or glass transition temperature.

Tensile Strength at Yield - Testing, Standards, Specs, Material

September 19, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties, Thin Film Applications

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The ability to accurately predict the behavior of coating materials under tension is crucial in ensuring the integrity and reliability of electronic components. This includes studying different materials' deformation and failure mechanisms when subjected to a tensile load. One key parameter that is used to quantify the ability of a material to withstand such loads is its tensile strength at yield.

What is Tensile Strength at Yield?

Tensile Strength at Yield indicates a material's ability to withstand loads and forces during its lifetime, making it crucial for designing structures and components that can endure various stresses. It is a vital measurement in numerous disciplines, such as engineering, manufacturing, aerospace, and automotive.

When a material is subjected to a tensile load, it experiences stress and undergoes deformation. The stress-strain curve, representing the relationship between the applied stress and resulting strain, provides valuable insights into the material's behavior. This curve can determine the ultimate tensile strength, the maximum stress the material can withstand before failure occurs.

The yield point is a critical parameter in studying tensile strength at yield. It refers to the point on the stress-strain curve where a significant increase in strain occurs with minimal or no increase in stress. The tensile strength at yield is the stress level at this point and represents the maximum stress a material can withstand without undergoing permanent deformation.

During the deformation process, materials can exhibit different types of behavior. Elastic deformation occurs when a material returns to its original shape upon removal of the load, while plastic deformation occurs when the material undergoes permanent changes in shape. Understanding the concepts of elastic and plastic deformation is essential in analyzing a material's behavior under tension.

Testing Methods, Equipment, and Standards Used for Measurement

Due to the importance of this mechanical material property, obtaining accurate Tensile Strength at Yield data is critical. Accurately measuring it requires appropriate testing methods, equipment, and adherence to specific standards. The most commonly used technique is the tensile test, where a sample material is subjected to an increasing axial load until it reaches its yield point. Sophisticated equipment, such as universal testing machines, performs these tests and obtains reliable measurements. Standard organizations, such as ASTM International, provide guidelines and standards for conducting these tests, ensuring consistency and comparability of results.

Standards and Specifications

Standards and specifications are crucial in ensuring the accuracy, reliability, and consistency of measurements. National and international organizations have established various standards to regulate this critical characteristic of materials.

Similarly, numerous national and international standards have been developed to guide the measurement and characterization of tensile strength at yield. These standards outline the specific testing methods, equipment, and conditions to ensure accurate and comparable results across different laboratories and industries.

The American Society for Testing and Materials (ASTM), International Organization for Standardization (ISO), and Deutsches Institut für Normung (DIN) are among the leading organizations that have established widely recognized standards for tensile strength at yield. Compliance with these standards is essential in ensuring test data's uniformity, reliability, and compatibility.

What Influences Tensile Strength at Yield?

Material composition plays a crucial role in determining values. Different elements and their proportions can significantly affect the mechanical properties of a material, including its yield strength. For example, increasing the amount of carbon in certain materials can enhance tensile strength at yield.

The microstructure of a material also plays a vital role in determining this value. Factors such as grain size, phase distribution, and dislocation density can impact the material's ability to withstand deformation before yielding.

Coating Material Selection and Design Factors

Because this mechanical property is crucial in determining various structures and products' overall reliability and safety, it should be closely considered during material selection. Every industry and application has unique requirements for choosing a coating material. Engineers must account for environmental conditions, load-bearing capacity, and durability requirements. They can select appropriate materials to meet the desired performance and safety standards by evaluating the tensile strength at yield requirements specific to each industry. A summary of requirements for particular applications is below.

Evaluating Tensile Strength at Yield requirements for different industries

Aerospace: In the aerospace industry, where extreme conditions and rigorous performance requirements exist, coating materials with exceptional tensile strength at yield are crucial. This property ensures aircraft components' structural integrity and safety, such as wings and fuselage, under immense stress during flight.
Automotive: This property is vital in automotive engineering as it affects vehicle structural stability. Manufacturers and designers prioritize coating materials with optimal values to enhance passenger safety and overall vehicle performance.
Consumer products: From household appliances to sports equipment, consumer products are designed to withstand daily usage and potential impacts. Tensile strength at yield is vital in ensuring that these products can withstand the forces they are subjected to without deforming or failing.

Importance in Coating Material Selection

Tensile strength at yield is a critical mechanical property used in coating material selection. It provides valuable information about the protective coating material's ability to withstand applied forces without permanent deformation. If a protective coating were to break, it could allow corrosives and contaminants to destroy electronic components, causing failure.

Design engineers rely on this property to evaluate and compare different coating materials, ensuring their suitability for specific applications. If you are designing an electronic component and need help determining which coating material is best for your product, please contact our engineers, or read additional information on thin film coating properties.

Elongation at Break - Definition, Testing, Material Selection

September 19, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties, Thin Film Applications

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Elongation at break is a key mechanical property that measures the deformation capacity of a material before it eventually snaps or breaks, providing insights into the material's behavior and performance. This crucial measurement is closely related to tensile strength, which determines a material's ability to withstand pulling forces without breaking.

The longer the elongation at break, the greater the material's flexibility and ductility. It represents how much a material can stretch or elongate under tension before reaching its breaking point.

In metals, elongation at break showcases malleability and ensures they can withstand deformation without fracturing easily. Plastics with higher elongation at break are more capable of enduring stress and strain without undergoing permanent damage. Understanding the importance of elongation at break helps select the right materials for diverse applications, ensuring optimal performance and durability.

Testing Methods for Elongation at Break

Elongation at break is a key indicator of a material's ability to stretch before reaching its breaking point, so accurate data is vital for material selection. To precisely determine this value, various testing methods are employed.

When conducting tests, manufacturing and quality control considerations play an essential role. These considerations include:

Ensuring that sampling is representative of the material being tested.
Using appropriate and calibrated testing equipment to obtain accurate measurements.
Following standardized testing procedures to maintain consistency.

By considering these factors, manufacturers can ensure the reliability and integrity of their testing results, which are critical for maintaining consistent material properties. Two methods of testing are described below.

Tensile Testing

Tensile testing involves subjecting a material sample to tension until it fractures. The sample is held between two clamps and pulled in opposite directions until it breaks. The amount of elongation before fracture is recorded and used to calculate the final value.

Elongation Testing

Elongation testing is another method utilized for measurement. Unlike tensile testing, this method focuses solely on measuring the elongation of a material sample without causing it to fracture. The sample is stretched until a specified strain value is achieved, and the resulting elongation is measured.

How to Calculate Elongation at Break

The elongation of the material sample at the point of fracture is measured by comparing the original length of the sample to its final length after fracturing. The percentage of elongation is then calculated by dividing the change in length by the original length and multiplying by 100.

Mechanical Properties and Plastic Deformation

Elongation at break is just one of the mechanical properties used to assess a material's performance. It is closely related to other properties like yield strength, resilience, and plastic deformation. Manufacturers often evaluate it alongside these properties to comprehensively understand a material's behavior.

For example, this property is a valuable measure of a material's ability to undergo plastic deformation. Plastic deformation refers to the permanent change in the shape of a material when subjected to stress. Materials with high elongation at break have greater plasticity and can undergo significant deformation without fracture.

Understanding the relationship between elongation at break and plastic deformation is crucial in various industrial applications. It allows engineers and manufacturers to select materials that can withstand the required stress and deformation without failure.

Consideration of Elongation at Break in Material Selection

Elongation at break is also widely used for material comparisons and benchmarking. By evaluating and selecting appropriate materials based on their desired levels of ductility and flexibility, industries can ensure that their products perform optimally under different operating conditions.

Materials with higher values are generally preferred in applications where the material needs to undergo extensive deformation without failure. On the other hand, materials with lower values may be desired for applications where high rigidity and resistance to deformation are required.

By considering elongation at break, engineers can make informed decisions regarding material selection and performance optimization, enhancing product reliability and customer satisfaction. If you are designing an electronic product that needs protective coatings and are having trouble identifying which material to choose, please contact our Applications Engineers for answers. Or if you are interested in learning more about thin film protective coating capabilities, such as such as elongation yield or Young's modulus of polymers, browse our site.

Young's Modulus of Polymers - Measurement, Calculation

September 19, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties, Thin Film Applications

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Young's Modulus is an important property, allowing engineers to select coating materials based on their desired stiffness. Understanding and manipulating the elastic Modulus of polymers is crucial for applications where strength, flexibility, or a combination of both is required.

What is Young's Modulus of Polymers?

Young's Modulus, also known as the elastic Modulus, is a fundamental property that characterizes the mechanical behavior of a material. It quantifies the relationship between stress (force per unit area) and strain (deformation) when a material is subjected to an external force or load.

For polymers, Young's Modulus determines how much the material will stretch or compress in response to applied stress. It measures the rigidity of the polymer chain structure. When comparing Young's Modulus between polymers and other materials such as metals and ceramics, polymers typically have lower values. This is because polymers have a more flexible molecular structure, allowing them to undergo more significant elastic deformation under applied stress, in contrast to metals and ceramics with more rigid atomic structures.

Factors Influencing Young's Modulus

Understanding the factors influencing Young's Modulus allows engineers to choose polymer materials with desired mechanical properties for specific applications. The following factors influence Young's Modulus of Polymers:

Molecular structure and chain flexibility: The arrangement and size of polymer chains determine their flexibility and, consequently, their Young's Modulus. Polymers with longer and more linear chains tend to have higher Young's Modulus values.
Degree of cross-linking and polymerization: Cross-linking refers to forming chemical bonds between polymer chains, increasing their rigidity and thus increasing Young's Modulus. Higher degrees of cross-linking result in higher Young's Modulus values.
Temperature and environmental conditions: Young's Modulus of polymers can vary with temperature and environmental conditions. The presence of moisture, for example, can affect the intermolecular forces within the polymer, leading to changes in Young's Modulus.

Measurement and Calculation of Young's Modulus

Measuring and calculating Young's Modulus is crucial to understanding the mechanical behavior of polymers. This value provides valuable insight into how a polymer will respond to applied stress and strain, making it essential in product design.

There are various experimental techniques used to measure Young's Modulus in polymers. These include:

Tensile testing and stress-strain curves: This technique involves subjecting a polymer sample to tension until it reaches its breaking point. The resulting stress-strain curve provides essential data for determining Young's Modulus.
Extensional methods: Uniaxial and biaxial extension tests measure Young's Modulus in specific directions. These methods help evaluate the anisotropic nature of polymers.
Other characterization techniques: Techniques such as nanoindentation and dynamic mechanical analysis can also be employed to measure Young's Modulus in polymers.

Calculation methods for Young's Modulus

Hooke's Law and stress-strain behavior interpretation play vital roles when calculating Young's Modulus:

Hooke's Law and its application to polymers: Hooke's Law states that the stress applied to a material is directly proportional to the strain it produces. This linear relationship allows for the calculation of Young's Modulus.
Interpretation of stress-strain behavior and determination of Modulus: By analyzing the stress-strain curve obtained from experimental data, the Modulus can be determined using mathematical methods tailored for polymers.

Role in Material Selection and Design

Young's Modulus helps engineers determine the stiffness and elasticity of polymers. Knowing Young's Modulus values allows them to select the appropriate material for a specific application. The higher the Young's Modulus, the stiffer the material will be, resulting in better resistance to deformation. This stiffness is crucial in applications where the polymer needs to withstand heavy loads or maintain its shape for a long time.

Some examples of how design engineers use Young's Modulus to select materials in different industries are listed below.

Automotive and aerospace applications: Young's Modulus is essential in designing components such as automotive body parts, airplane wings, and fuselages. It helps engineers ensure the materials can withstand the required forces and maintain their shape during operation.
Medical and healthcare applications: Young's Modulus is a consideration when developing medical devices, prosthetics, and implants. The Modulus ensures that the materials provide the necessary support, flexibility, and performance for patient safety and comfort.
Consumer goods and packaging: Young's Modulus comes into play in designing everyday products such as bottles, containers, and packaging materials. It helps determine the polymers' rigidity, flexibility, and impact resistance, ensuring they meet the specific requirements of the intended applications.
Industrial applications: Engineers can use the measure of stiffness or rigidity of a material to predict how polymers will behave under various conditions common in harsh industrial environments.

Relationship Between Young's Modulus and Product Performance and Durability

Because Young's Modulus directly affects a polymer's behavior under different loads and stresses, engineers can make informed decisions about material selection, design structures that can withstand specific loads, and ensure the safety and reliability of polymer-based products.

The knowledge of Young's Modulus allows for optimizing material properties, such as flexibility and strength, to meet the unique requirements of various industries. Whether in the automotive, aerospace, or medical field, an understanding of Young's Modulus enables the development of innovative solutions that are tailor-made for specific applications.

If you are an engineer involved in product design and would like guidance in selecting a suitable coating material for your application, please contact our team today. Alternatively, if you want to learn more about thin film properties, including elongation yield, elongation at break, or tensile strength at yield, browse our site.

Water Vapor Transmission Rate - Standards, Testing, Material

September 14, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties, Thin Film Applications

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In the world of electronics, moisture control is of utmost importance. High water vapor transmission rate (WVTR) can pose significant risks to sensitive electronic devices. When moisture enters electronic components, it can lead to various issues, including corrosion, short circuits, and malfunctioning. These risks can result in costly repairs, product failures, and even safety hazards.

Manufacturers continually strive to create smaller, faster, and more powerful electronics. However, these advancements also often make the devices more susceptible to moisture damage. Implementing effective moisture control measures during the design and manufacturing process is essential to ensure the longevity and reliability of electronic components.

Water vapor transmission refers to the movement of water vapor through a material or substance. The water vapor transmission rate is a pivotal property for moisture control, and as such, measuring and managing WVTR is a priority in many applications.

Understanding Water Vapor, Transmission, and Vapor Transmission

Water vapor refers to the presence of water in a gaseous state. Under certain temperature and pressure conditions, water vapor can condense into liquid water.

Transmission refers to the movement of any substance, whether liquids, gases, or solids, from one side of a barrier to the other. This movement can occur through various means, such as diffusion, permeation, or evaporation. Vapor transmission, on the other hand, specifically relates to the movement of water vapor molecules through a barrier.

Vapor transmission plays a crucial role in moisture control. Without the ability for water vapor to move freely through materials, moisture can become trapped, leading to mold growth, structural damage, and product degradation. By allowing water vapor to escape, vapor transmission helps prevent excessive moisture buildup.

Factors affecting vapor transmission

Several factors influence the rate of vapor transmission. These include temperature, pressure, and humidity.

Temperature variations can affect the rate water molecules transition between vapor and liquid states. Higher temperatures generally increase the speed of vapor transmission.
Pressure differentials between the two sides of a barrier can also impact vapor transmission. In some cases, pressure differentials can hinder or enhance the movement of water vapor.
Humidity levels, which measure the amount of water vapor in the air, can greatly influence vapor transmission. Higher humidity often leads to higher vapor transmission rates, while lower humidity may restrict the movement of water vapor through materials.

Water Vapor Transmission Standards and Testing

The ASTM standards outline the procedures and techniques for conducting WVTR tests, ensuring consistency and accuracy across different laboratories and testing facilities. These standards provide guidelines on sample preparation, test conditions, and data analysis, allowing for reliable and comparable results.

Overview of Permeability Testing Methods and Techniques

Permeability testing refers to the evaluation of how easily water vapor can permeate through a material or film. Several methods are available to measure WVTR, including the gravimetric method, the desiccant method, and the electrical measurement method. Each method has its advantages and limitations, and the choice of method depends on factors such as the material being tested and the required accuracy. You can read more about these methods at the ASTM website.

Importance of Accurate Testing for Reliable WVTR Results

Accurate testing determines a material's true water vapor transmission rate. By following ASTM standards and utilizing appropriate testing methods, manufacturers can ensure that their products meet the necessary performance requirements and provide optimal moisture control.

Learn about relevant standards such as Ingress Protection Standards and NEMA Ratings.

Film and Polymer Materials

Thin films play integral roles in creating effective moisture barrier systems. These materials are designed to prevent water vapor passage, thereby protecting products and structures from moisture damage.

Specific properties and characteristics become priorities when evaluating coating materials for moisture control. Engineers should consider the following:

Water vapor permeability: measures how easily water vapor can pass through a material. Lower permeability indicates better moisture resistance.
Tensile strength: the ability of the coating material to resist breaking or tearing under tension
Elongation at break: The maximum elongation or stretch a material can undergo before breaking. Higher elongation allows for flexibility and resistance to tearing.
Chemical resistance: the resistance of the material to chemical substances, preventing degradation and maintaining its moisture control properties
Transparency: In specific applications, it is essential for the polymer material to maintain transparency, allowing consumers to evaluate products visually.

If you need a coating material with a low water vapor transmission rate or have questions about choosing suitable materials, contact our Applications Engineers for a DFM consult. Or, you can learn more about protective thin film coating properties.

Transparent Polymers - Applications, Material Selection

September 14, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties, Thin Film Applications, Value of Coatings

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Transparent polymers offer optical clarity and the ability to transmit light. With various applications across various industries, these polymers have gained popularity for their unique properties and versatility. Common transparent polymer types include acrylics, polycarbonates, parylenes, and polyurethanes. The molecular arrangement and morphology of transparent polymers play a crucial role in their transparency. Transparent polymers typically comprise transparent monomers that polymerize to form a solid material. A uniform and amorphous structure is of paramount importance in achieving optical clarity.

Read about refractive index, another optical property.

Applications of Transparent Polymers in Various Industries

Optics and Optical Devices

Transparent polymers are extensively used to produce lenses, optical fibers, LEDs, and displays. Due to their excellent optical clarity and refractive properties, these polymers contribute to the functionality and performance of these devices. They enable the transmission and manipulation of light, essential for achieving optimal performance in optics and optical devices.

Coatings and Films

Transparent polymer coatings and films are widely used for various applications, including protection, durability, and aesthetic enhancement. These coatings and films are applied on glass, metals, and electronics surfaces to provide a protective layer while maintaining transparency. Transparent polymer coatings and films also resist scratches, chemicals, and UV radiation.

Renewable Energy

They play a significant role in the fabrication and encapsulation of solar panels. They are transparent encapsulant materials that allow sunlight to be absorbed and transmitted to the photovoltaic cells within the solar panels. Transparent polymers help maximize the efficiency of solar panels by ensuring optimal light absorption and transmission.

Biomedical Applications

These polymers are extensively used in biomedical imaging, drug delivery systems, and tissue engineering. They enable clear visualization in imaging techniques and provide a platform for developing advanced drug delivery systems.

Displays and Electronics

Some of these polymers play a crucial role in the development of touch screens, flexible displays, and transparent conductive films used in electronics. They enable light transmission while providing electrical conductivity, making them essential components in the construction of displays and electronic devices. They also contribute to the production of sleek and high-performance electronic devices.

Coating Material Selection

Transparency, durability, and versatility make these polymers ideal for numerous applications. Transparent polymers enable technological advancements and enhanced user experiences from optical lenses to display screens. If you require this type of coating material for your product design and would like to speak to an engineer, HZO can help. Reach out today. Or, you can stay and read more about coating properties, including thermal conductivity, linear coefficient of expansion, and glass transition temperature.

Biocompatible Coatings - Coating Techniques, Applications, More

September 13, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Process, Coating Properties, Thin Film Applications

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Biocompatible coatings seamlessly integrate with the human body, offering benefits through their ability to promote healing and prevent adverse reactions. They can improve patient outcomes, reduce complications, and enhance device functionality. As such, biocompatible coatings have become an indispensable tool in various medical applications.

What is Biocompatibility, and What Affects the Biocompatibility of Coatings?

Biocompatibility refers to the ability of a material to function without causing any harmful effects to the living tissues or organs it comes into contact with.

Several factors influence the biocompatibility of coatings. One such factor is the material composition. The choice of materials used in a coating can significantly impact its compatibility with the human body. Additionally, the surface properties of the coating play a vital role in determining its biocompatibility. Roughness, porosity, and surface energy can affect how the coating interacts with biological tissues and fluids.

When it comes to achieving biocompatibility in coatings, there are key considerations. First and foremost, the material should be non-toxic and non-allergenic. It should not trigger any adverse immune responses or elicit any toxic effects. Furthermore, the coating should withstand the physiological environment it will be exposed to, such as changes in pH, temperature, and mechanical stress.

Coating application processes also play a significant role in achieving biocompatibility. The application technique must ensure uniform coverage and adherence. Proper surface preparation and application techniques are essential to avoid issues arising from poor coating adhesion or inconsistencies.

Why are Biocompatible Coatings Important?

Biocompatible coatings can significantly influence the body's response to medical devices and implants. A well-designed biocompatible coating can minimize inflammatory responses, prevent bacterial adhesion, and promote tissue integration. Furthermore, by providing a protective and biologically compatible barrier, these coatings enhance the safety and effectiveness of medical devices, improving patient outcomes.

There have been several successful applications of biocompatible coatings in medicine and biomedical engineering. Here are a few examples:

Orthopedic implants: Biocompatible coatings have been used on orthopedic implants to improve their longevity and reduce inflammation and tissue rejection.
Drug delivery systems: Coatings have been developed to encapsulate and protect drugs, allowing for targeted delivery and controlled release within the body.
Stents: Biocompatible coatings on stents help to prevent blood clot formation and promote healing in cardiovascular applications.
Dental implants: Coatings on dental implants enhance biocompatibility, improving the integration of the implant with the surrounding bone.

Coating Technologies

Various coating technologies are employed to achieve biocompatibility in different medical devices. These technologies involve using specific materials and techniques to create coatings that meet the required standards:

Chemical Composition

Different biocompatible coating materials, including polymers, such as Parylene, ceramics, and metals, are used. Each type has its unique characteristics and advantages for medical applications. Polymers, for example, are known for their flexibility and ability to mimic natural tissues. Ceramics offer excellent wear resistance and can provide a stable surface for cell growth, while metals are valued for their durability and strength.

Coating Techniques

Each coating technique has its advantages and limitations. The selection of a particular method depends on factors such as the desired coating properties, the substrate material, and the intended application. The deposition of biocompatible coatings requires specific techniques to ensure uniformity and adherence to the substrate. Several coating techniques are commonly employed in the medical industry, including:

Chemical vapor deposition (CVD): In this technique, a precursor gas is introduced into a chamber and reacts to form a coating on the surface of the substrate. CVD offers excellent coating conformity and is frequently used for coating stents and catheters.
Electrochemical deposition: Also known as electrodeposition, this technique involves using an electric current to deposit a material onto a substrate. It is typical for coating electrodes and medical implants.
Dip coating: This technique entails immersing the substrate into a bath of the coating material and then withdrawing it at a controlled rate. Dip coating provides a uniform and controlled coating and is often used in the fabrication of medical devices.
Spray coating: The coating material is atomized and applied to the substrate in a fine spray. This is a popular technique for coating dental implants and prosthetics.

Biocompatible Coatings Applications

Biocompatible coatings can be employed in manufacturing electronic devices, food processing equipment, and cosmetic products, among others. With their ability to provide a safe and reliable surface, biocompatible coatings offer advantages beyond the medical field.

However, within various areas of medicine, biocompatible coatings play a crucial role in enhancing the compatibility of medical devices, improving tissue engineering techniques, and revolutionizing drug delivery systems. These coatings have transformed the field of medicine by reducing rejection and adverse reactions and improving the overall efficiency of medical interventions. Three use cases are described below.

Medical Implants

One of the critical applications of biocompatible coatings is in the field of medical implants. For instance, in orthopedic implants, biocompatible coatings create an optimal environment for the implant to integrate seamlessly with the surrounding tissues and bones. Similarly, dental and cardiovascular implants benefit from biocompatible coatings, promoting long-term stability and functionality.

Drug Delivery Systems

Biocompatible coatings have revolutionized the field of drug delivery systems by improving stability, enhancing bioavailability, and enabling targeted drug delivery. The efficacy and safety of drug delivery are significantly improved by coating drug carriers such as nanoparticles, microparticles, and implants with biocompatible materials. These coatings protect the drugs from degradation, facilitate controlled release, and ensure targeted delivery to specific tissues or cells.

Biomedical Devices

Biocompatible coatings find extensive applications in various biomedical devices, including biosensors, microfluidic devices, and prosthetics. These coatings enable seamless integration and interaction with biological systems, enhancing the device's functionality and reducing the risk of adverse reactions. For example, biocompatible coatings on biosensors allow accurate and reliable detection of biomarkers, while coatings on prosthetic limbs improve their integration with the human body and enhance user comfort and mobility.

Factors Influencing Biocompatible Coating Selection

Selecting the most suitable material for a specific application is essential to ensure optimal biocompatibility and overall performance of the coating. There are various factors to consider when selecting materials for specific medical applications. These factors include:

Chemical composition: The specific chemicals used in the coating formulation can significantly influence its biocompatibility with the surrounding environment.
Surface interactions: Understanding how the coating interacts with the surrounding biological tissues and fluids is crucial to ensure proper biocompatibility.
Thickness and uniformity: The thickness and uniformity of the coating play a vital role in its ability to protect the underlying substrate and provide the desired properties.
Physical properties: The physical properties, such as hardness, flexibility, and adhesion strength, must be considered when selecting a coating for a specific application.

Please contact our engineers if you require a biocompatible coating material for your application or have questions about protective thin film coating properties. Meanwhile, please browse our resource section to learn about other relevant properties, such as tensile strength, yield elongation, and corrosion resistance.

Dissipation Factor - Definition, Measurement, Variables

September 12, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Dielectric materials are crucial in various industries and applications, serving as insulators, substrates, or capacitors. One important characteristic often evaluated in dielectric materials is their dissipation factor. The dissipation factor, also known as the loss tangent or tan δ, is a vital parameter that measures the dielectric losses in electrical systems and components. It quantifies the energy dissipated as heat when an alternating current (AC) signal passes through an insulating material or a capacitor.

Why is Dissipation Factor Important?

This property provides valuable insight into the performance of dielectric materials. It measures the efficiency with which a dielectric material dissipates energy in the form of heat when subjected to an alternating current (AC) or high-frequency signal.

By analyzing this value, engineers can detect potential issues such as insulation breakdown, heat generation, and power loss, enabling them to effectively design and optimize electrical systems. Whether in high-frequency applications, power electronics, or telecommunications, the dissipation factor assists in selecting the appropriate materials, reducing energy loss, and enhancing electrical equipment's overall efficiency.
A high dissipation factor can indicate potential problems such as inefficient energy transfer or excessive heat generation in dielectric materials. By assessing this data, engineers can determine if a material is suitable for a specific application or needs replacing.

Measurement Techniques

The dissipation factor is calculated by dividing the loss tangent of a dielectric material by its capacitance. The loss tangent is the ratio of the dissipated power to the stored energy in the material. There are several ways to determine the dissipation factor of various materials accurately. Professionals can use these techniques to obtain precise data and evaluate the performance and reliability of materials.

Bridge Method

The bridge method is a common measurement technique. It uses a bridge circuit consisting of resistors, capacitors, and inductors. By balancing the bridge, engineers can determine the material's dissipation factor under test.

Parallel-Plate Method

The parallel-plate method is another popular technique. It involves placing the material between two parallel plates and applying an alternating voltage across them. The dissipation factor is determined by measuring the power loss in the material.

Guard-Ring Method

The guard-ring method is a technique that minimizes the effects of stray capacitance during measurement. It involves placing a guard ring around the measurement electrodes to prevent current leakage due to the stray capacitance. This method helps to improve accuracy.

Variables Affecting Dissipation Factor

Several factors can influence the dissipation factor, affecting the efficiency and performance of electrical systems. Engineers and designers can optimize electrical systems by understanding and considering these factors, ensuring efficient and reliable operation.

Temperature

Temperature plays a significant role. As the temperature increases, molecular motion and energy losses increase, leading to a higher value. It is important to consider the temperature range in which a material will be used to ensure its dissipation factor remains within acceptable limits.

Dielectric Loss

Dielectric loss refers to the energy lost as heat due to the interaction between the electric field and the dielectric material. Materials with higher dielectric losses tend to have higher dissipation factors. Selecting materials with low dielectric loss can help minimize dissipation and improve system performance.

Frequency of Operation

The frequency of operation has a direct impact. At higher frequencies, the energy losses from the materials increase significantly, leading to an increased value. It is essential to consider the operating frequency when evaluating the dissipation factor of materials for electrical systems.

Resistance in the Circuit

The resistance in the circuit also contributes to the dissipation factor. Higher resistance causes larger energy losses and a greater value. Minimizing resistance through proper circuit design and selecting low-resistance components can help reduce the overall dissipation factor.

Material Selection

The dissipation factor provides valuable insights into the electrical behavior of components, enabling manufacturers to make informed decisions regarding their application in different industries. This value is relevant across various industries heavily relying on electrical components. Industries such as telecommunications, power generation, aerospace, and automotive require strict adherence to quality standards to ensure optimal performance and safety.

Engineers can compare materials' performance at high frequencies by evaluating this property. This evaluation allows them to select materials with lower dissipation factors, which result in reduced energy losses and improved system efficiency. Furthermore, optimizing this property can also lead to increased power handling capabilities and improved reliability. If you are designing an electronic product and need help selecting a protective coating with beneficial electrical properties, please contact our team for a consultation. Or, you can learn more about thin film coating properties.

Volume Resistivity - Definition, Measurement, Product Design

September 12, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Whether designing circuit boards or protecting electrical components, knowledge of the volume resistivity of coating materials plays a pivotal role in creating efficient and reliable electronic products. This critical measurement refers to the ability of a material to resist the flow of electric current within its volume. In other words, it measures how well a substance conducts or insulates electricity.

Defining Volume Resistivity

Volume resistivity refers to a material's resistance per unit volume when an electric field is applied. It is measured in ohm-meters (Ω·m) and depends on the material's nature and composition.

One way to understand this property is by comparing it to electrical conductivity. While volume resistivity measures the resistance to the flow of current, electrical conductivity measures how easily current flows through a material. In other words, it is the inverse of electrical conductivity. Volume resistivity is especially important in coating materials used for electrical insulation. Insulating materials like polymers or ceramics need high values to prevent electrical current leakage and ensure the circuit's integrity.

Measurement

Due to its importance, the accurate measurement of volume resistivity is essential to understanding the electrical conductivity of materials. By determining how well a coating material can resist the flow of electric current, engineers can assess its suitability for a wide range of applications.

Several techniques are common. One such method is the four-point probe technique, which involves passing a known current through a material and measuring the voltage drop across four evenly spaced points. This method enables precise calculations of the material's resistivity. Another popular technique is the two-point method. This approach passes a current through the material using two electrodes, and the voltage drop is measured. By applying Ohm's Law, the resistivity can be easily determined.

Specialized equipment is necessary to measure this value. This equipment includes multimeters, which can accurately measure voltage and current. Custom-built setups are often employed for specific applications to ensure precise measurement results.

Influencing Factors

Various factors can influence the volume resistivity of a coating material. These factors can alter the resistance properties of a material and potentially affect its performance in electrical applications. They include the following:

Material composition - the composition of a material plays a crucial role in determining its volume resistivity. Different materials have different electrical properties, which can significantly influence their resistance to electric current flow.
Molecular structure - materials with tightly packed and well-ordered molecular structures tend to have higher resistivity as the movement of free electrons is restricted.
Impurities - even small amounts of impurities can disrupt the movement of electrons, leading to changes in the coating material's electrical resistance.

Relationship Between Coating Materials and Volume Resistivity

Polymer materials have different volume resistivity values, determining their ability to conduct or resist electrical current. The volume resistivity of a polymer is directly influenced by its molecular structure and composition. Some examples of polymer materials with high values include polyethylene and polypropylene. These materials are commonly used in cable insulation and high voltage applications, where electrical current needs to be contained. On the other hand, polymer materials with low values, such as conductive polymers and carbon-filled composites, are often used as electrical conductors. They are suitable for applications requiring efficient electrical current flow.

Why is This Property Important for Product Design?

Volume resistivity is a critical value that helps determine the suitability of coating material for specific applications. Engineers can select the most appropriate materials to ensure optimal performance and safety by knowing how conductive or insulating a substance is. Additionally, understanding this property helps diagnose and prevent electrical failures in electronic products. Analyzing the volume resistivity of protective coating material within an electrical system allows potential issues, such as short circuits or unexpected voltage drops, to be identified and rectified before they cause significant damage or failures. This proactive approach saves time and money while enhancing the system's reliability. Last, volume resistivity is essential in complying with industry standards and regulations. Many sectors, including electronics, automotive, and aerospace, have stringent requirements for electrical systems. By ensuring that materials used in these systems possess the appropriate volume resistivity values, businesses can meet these standards and ensure the longevity of their products.

Significance in Circuit Design

In circuit design, selecting coating materials with appropriate volume resistivity is paramount. This property plays a significant role in ensuring electronic devices' proper functioning and performance. By selecting materials with appropriate volume resistivity, circuit designers can ensure the proper operation of different components, minimize the risk of electrical failures, and enhance the overall functionality of the circuit.

Overall, this is a critical factor to consider during circuit design. It not only influences the performance and efficiency of electronic devices but also allows for the optimization of circuit design by selecting materials based on their electrical properties. If you are searching for a protective coating with volume resistivity that meets the criteria for your application, please contact us; we may be able to help. For more information about the critical electrical properties of coating materials, please visit our coating properties page.

UL94 Coating Material - Testing Method, Material Selection

September 8, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Fire safety compliance is an indispensable aspect across various industries. One crucial benchmark in fire safety compliance is UL94, a widely recognized standard for flammability testing of plastic materials. By evaluating the flammability characteristics of different materials, UL94 ensures that products meet the required safety standards and regulations.

What is UL94?

UL94 is a standard for evaluating plastic materials' flammability in various industries. It provides an objective and reliable assessment of the fire resistance properties of these materials.

UL94 is an abbreviation for Underwriters Laboratories Standard 94, first introduced in 1972. Underwriters Laboratories (UL) is a global safety certification company that tests and certifies a wide range of products for their safety and performance. UL94 is one of the many standards developed by UL to ensure the safety of products and materials.

The role of this standard in product and material safety assurance cannot be overstated. It helps engineers and manufacturers identify potential fire hazards by clearly demonstrating materials' flammability properties. This information mitigates risks and leads to the development of safer products.

Flame ratings, such as V-0, V-1, V-2, HB, etc., indicate a material's ability to self-extinguish or resist flame propagation. Materials with higher flame ratings provide greater confidence in the product's safety and fire resistance. Understanding these ratings is essential in assessing the fire performance of materials and ensuring their compliance with safety standards; therefore, accurate data is critical.

Learn about other standards, such as Ingress Protection Standards and NEMA ratings.

Testing Methodology

The UL94 testing methodology is a standardized procedure used to determine the flammability characteristics of materials. The UL94 testing methodology subjects test specimens to controlled flame exposure, providing valuable information to manufacturers, regulators, and consumers.

Several test methods are used in testing, including vertical burn, horizontal burn, and others. Each test method simulates specific fire scenarios and assesses different aspects of a material's flammability. Before testing, specimens are prepared according to particular requirements. This preparation includes cutting them into proper dimensions, removing any surface coatings, and ensuring consistency in sample preparation across different tests.

UL94 testing occurs under specific standard test conditions, such as ambient temperature and flame duration. These conditions simulate real-life fire scenarios and allow for reliable material comparisons. Flame ratings are assigned based on specific criteria, such as the material's ability to self-extinguish within a particular time frame or its resistance to flame propagation. These criteria vary depending on the test method applied.

Material Selection

Understanding the relationship between material characteristics and fire resistance is crucial when choosing suitable plastic materials. UL94 testing helps engineers evaluate different materials' flammability, ignition, and burning characteristics to select the most appropriate options, ensuring that the chosen materials meet safety requirements and minimize potential risks.

When selecting coating materials for specific applications, there are several key considerations. These include the intended use, environmental conditions, mechanical properties, and chemical and fire resistance. A comprehensive understanding of UL94 test results enables engineers and designers to make well-informed decisions regarding material selection. If you are looking for a UL94-rated protective coating material or have questions for our engineering team, please contact us today. Or you can learn more about thin film protective coating properties, such as dielectric constant, Young's Modulus, biocompatibility, and glass transition temperature.

Elongation Yield: Overview, Unit of Measure, Data and Testing

August 29, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Elongation yield refers to the maximum amount of deformation a material can undergo before it experiences a permanent change in shape or size. This property is fundamental in determining various coating materials' mechanical strength and behavior, making it an essential factor in design engineering and product design.

Understanding how this property affects material performance is crucial in determining the suitability of coating material for a particular application. It directly affects the material's ability to deform without breaking and sustain loads without failure. This high-level overview will discuss elongation yield and its implications for product design.

Elongation Yield: Material and Unit of Measure

Elongation yield can be measured in various coating materials, including metals, polymers, and composites. Coating materials such as metals with higher values typically exhibit greater ductility, the measure of a material's ability to deform before fracture.

On the other hand, coating materials with a lower elongation yield tend to be less ductile and more prone to brittle behavior. They have limited ability to deform before reaching their breaking point. Such materials are usually more suitable for applications that require high strength and rigidity but not necessarily significant deformation.

Polymers, including plastics and rubber, display higher values than metals, enabling them to withstand extensive stretching or bending before breaking.

Composites, which consist of two or more different material components, can possess varying characteristics depending on their composition. The individual materials within a composite can have different abilities to undergo elongation yield, making the overall behavior complex.

Unit of Measure

Two standard units of measure are used to quantify elongation yield: percentage and millimeters.

The percentage unit of measure represents the elongation yield as a percentage of the original length of the material. For example, if a metal specimen stretches 10% before breaking, it has elongated by 10% of its original length.

On the other hand, millimeters are used to measure the actual physical elongation of a material. This unit of measure provides a more tangible representation of the deformation a material undergoes before reaching its breaking point.

Both units of measure have their advantages and are suitable for different applications. The choice between percentage and millimeters depends on the material type, testing specifications, and industry standards.

BL0141-Yield Elogation-Inline 1

Data and Testing Method for Measuring

When determining a material's elongation yield, reliable data and thorough testing methods are essential to ensure accurate measurements and a deeper understanding of how a material will perform under various conditions. The data obtained during material testing provides valuable insights into the behavior of a material and its elongation yield. It includes measurements such as strain and stress, which calculate values.

Strain refers to the deformation experienced by a material when subjected to external forces. It is measured as the change in length divided by the original length.
Stress is the force applied per unit area and is assessed by dividing the applied force by the original cross-sectional area.

By analyzing the relationship between stress and strain, engineers can identify the point at which the material starts deforming permanently, known as the elongation yield point.

Overview of the Different Testing Methods Used

Various testing methods are employed to measure this property, each offering advantages and limitations. Tensile testing, for example, is commonly used to evaluate a material's mechanical properties, including elongation yield.

In tensile testing, a material sample is subjected to controlled tension until it reaches its elongation yield point. The resulting data helps determine the material's ability to withstand loads and deformations.

On the other hand, impact testing measures the energy absorbed by a material when it fractures under sudden stresses. This method provides valuable insights into the material's toughness and resistance to sudden impacts.

Other testing techniques, such as bend and hardness tests, can also provide insights. The bend test involves subjecting a material to bending forces to determine its flexibility and resistance to deformation. On the other hand, the hardness test measures the material's resistance to indentation, indirectly indicating its elastic deformation capabilities.

Specific standards established by regulatory bodies and industry organizations govern the testing procedures. These standards ensure consistency and comparability of test results across different laboratories and manufacturers.

Importance in Material Selection and Design

Engineers and designers can make informed decisions regarding coating material by considering the elongation yield. They can determine the material's capacity to stretch and deform before reaching its breaking point, safeguarding the reliability of the end product.

Moreover, understanding the elongation yield can also help optimize designs, reduce material waste, and enhance overall efficiency. Engineers can create designs that balance strength, flexibility, and cost-effectiveness by accurately predicting the coating material's behavior based on elongation yield values.

Electronic product reliability hinges on protective coating durability. If a coating breaks in any way, it could open the door to corrosives, chemicals, and other contaminants that could cause electronics to stop working. Therefore, understanding the elongation yield value is vital in ensuring electronic products' safety, durability, and performance in real-world applications. If you need help identifying the best coating material for your application, please contact our Applications engineers for a DFM consult. Alternatively, you can learn more about our coating protection capabilities, including Young's modulus, elongation at break, and tensile strength at yield.

Difference Between Water Resistant, Repellent, & Proof

August 10, 2023 / by Mallory McGuinness-Hickey posted in Protection Capabilities

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If you're looking for the highest quality protection from the inside out, contact HZO today.

We all see references to waterproof, water-resistant, and water-repellant devices being thrown around on electronic products and printed circuit boards. The big question is: What’s the difference? There are a lot of articles written on this topic, but we figured we would throw in our two cents as well and take a closer look at the differences between all three terms, with a specific focus on the world of devices.

First of all, let’s start with some quick dictionary definitions of waterproof, water-resistant, and water-repellent, as given by the Oxford English Dictionary:

Water-resistant: able to resist the penetration of water to some degree but not entirely
Water-repellent: not easily penetrated by water, especially as a result of being treated for such a purpose with a surface coating
Waterproof: impervious to water

What Does Water-Resistant Mean?

Water resistance is the lowest level of water protection of the three. If a device is labeled as water-resistant, it means that the device’s construction makes it more difficult for water to get inside of it or possibly that it is coated with a very light substance that helps improve the device’s chances of surviving an encounter with water. Water-resistant qualities are great for products such as watches because they help those products withstand light rain or washing your hands.

What Does Water-Repellent Mean?

Water-repellent coatings are the next step up from water-resistant coatings. Devices labeled as water-repellent have properties that repel water from them, which makes them hydrophobic. Water-repellent devices have a better chance of surviving a watery encounter. Most have thin-film nanotechnology, which can coat the inside and outside of an electronic device. Many companies claim water-repellency, but the term is heavily debated because a durable water-repellent is rare and because of all the questions and unpredictable elements associated with it.

What Methods Can You Use to Make Electronic Components Water-Repellent?

Seals and enclosures can help you make your product resistant to moisture by preventing water from leaking in. These can add bulk and weight to PCBs and products and can become dislodged if a consumer drops a product or bumps into it. Humidity in the Application environment can also seep in. If your project needs slight protection, seals and enclosures could be a good solution.

What Does Waterproof Mean?

Defining “waterproof” is simple, but the concept is more complicated. There is no established industry standard to classify a device as waterproof. The closest thing currently available, as far as a rating scale is concerned, is the Ingress Protection Rating scale (or IP Code). The IP Code assigns items a rating from 0-8 in terms of how effective the device is at keeping water from entering into it, a process called the ingress of water. One major flaw in this rating system: What about companies like us here at HZO who are not concerned about keeping water out of a device to save it from water damage? Our coatings allow water inside devices, but the waterproof material we coat them with protects them from any possible water damage. HZO’s services have a different intention than the effect the IP scale can measure. Still, our coatings help you protect your electronic devices from water damage.

Companies take a measured risk when labeling a product as waterproof. Most consumers assume that waterproofing is a permanent condition. Still, devices exposed to “waterproofing” can face water damage in certain situations.

Using the term waterproof can also be considered a risky move for many companies. This is because "waterproof" usually communicates that this is a permanent condition and that whatever has been ‘waterproofed’ will never fail due to contact with water–no matter the situation.

With all the controversy surrounding the correct use and results associated with these terms, it’s no wonder many people use them incorrectly. Unsurprisingly, the products labeled as water-resistant, water-repellent, or waterproof are often misrepresented due to incorrect labeling. The words almost need new definitions with how far technology has come since these terms were first used. We also need a standard to measure a device’s waterproof qualities and represent the possibilities and kinds of technology like HZO that are commercialized and available to device makers now. This outdated scale can’t measure the power of our coatings.

How Can You Make a PCB Submersible?

HZO Parylene protects PCBs from full submersion for years. Parylene is a conformal coating used to protect sensors, PCBs, and components from water. Parylene has stronger barrier properties than traditional polymer coatings, such as silicone, acrylic, or epoxy.

HZO-Coating-Raspberry-Pi-1

What About Splashproof?

A splashproof product has a limited ability to resist water damage and is not immersible. For example, if you take your splashproof headphones with you on a run, they’ll be safe from sweat or droplets from your water bottle, but they won’t survive falling into a puddle.

Using the IP scale can demonstrate the differences between splashproof vs. waterproof products. Most waterproof electronics have an IP67 rating. A product qualifies as splashproof if it has an IP44 rating.

The scale from splashproof to waterproof includes:

IP44. An IP44 product withstands splashes from any direction, making it splashproof. These products are safe from solid materials larger than 1 millimeter.
IP55. These products resist low-pressure jets from any direction. IP55 products also have some protection against dust.
IP66. An IP66 product can withstand strong jets from any direction and completely protect against dust.
IP67. These products are suited for complete immersion at a depth of 1 meter for 30 minutes. This distinction qualifies them as waterproof. They also have total protection against dust.

An HZO Protected World

Because of the advanced level of protection available for electronics that protect them from water, sweat, other liquids and corrosion, the need for new standards is necessary to raise the bar in the minds of consumers. That’s why HZO is seeking to create an HZO Protected World and asking for people everywhere to help us tell the device makers of the world that we want electronics that have better, more reliable protection. Protection from the Inside Out.

Top Electronics Manufacturing Industry Publications

June 15, 2023 / by Mallory McGuinness-Hickey posted in Resources

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If you work in the electronics manufacturing industry, you are likely plagued with information overload, whether you are an engineer, purchasing professional, or business-oriented decision-maker.

For example, one study shed light on the sheer volume of information electronics design engineers must search for and select. In the research, the engineers reported that one of the most significant burdens associated with their job was identifying and selecting dozens of technical documents, best practices, evaluations, product searches, design tools, and information on regulatory requirements.

With all the information-seeking that people who work in electronics manufacturing must do, spending extra time wading through general news, analysis, press releases, and events to find topical, relevant content only adds to the frustration.

As a technology company involved in the industry, we know this problem too well. That’s why we have compiled a list of what we consider to be some of the best electronics manufacturing industry publications (in no particular order) and how to use these resources best.

1. Circuitnet (Link)

Circuitnet digs through the seemingly unending influx of articles, discussions, news, and features to deliver news and information relevant to the world of electronics manufacturing. The site features an “Ask the Experts” panel, where industry leaders weigh in on questions you may have, an industry calendar lists events essential to electronics manufacturing, and a technical papers section can be used to access technical content for free (although you will have to exchange basic information and email). You can use the search bar if you cannot find what you are looking for immediately.

How to use this resource:

While the Circuitnet site is robust, it also sends a news digest to subscribers’ inboxes every business day. This newsletter is a quick way to stay updated on information and trends pertinent to you, corporate or product announcements that serve as helpful tips, and industry events. Circuitnet also publishes more than forty feature articles a month on PCBs, the assembly process, and packaging and design, so you can ensure your knowledge is current.

CircuitNet’s Ask the Expert Panel

2. Circuits Assembly Magazine (Link)

Circuits Assembly Magazine provides fabricators, suppliers, and industry designers with best practices and insights to inform them about electronics industry trends. The website features podcasts, which you can easily access from the homepage, covering various topics from reliability to thermal management. Along with news and features, another section lists relevant press releases to keep you updated with industry developments.

How to Use this Resource:

Every month, Circuits Assembly Magazine offers a digital magazine that you can easily read on your computer, tablet, or phone. The magazine is also available in print, but we prefer the digital type, as it is easy to scroll through and quickly find articles of interest.

A Sample of This Month’s Circuits Assembly Magazine Edition

3. SMT Today (Link)

SMT Today integrates traditional communication (including a bi-monthly print magazine) and the latest technology to keep readers in the electronics industry current. On this site, you will find a newsletter, electronics, industry news, an up-to-date industry event calendar, and separate sections dedicated to equipment, materials, and software/integration news.

How to use this resource:

While you can sign up for the newsletter or read the magazine, the streamlined, organized interface of the website allows you to find what you are looking for quickly. We love to go to the homepage and use the menu bar to filter out the information we need immediately.

4. SMTnet and the Express Newsletter (Link)

SMTnet is a web portal dedicated to the electronics industry covering PCB assembly, Surface Mount Technology, and EMS process, from concept to delivery. This site is relevant to any industries involved in electronics, including information for engineering personnel, purchasing agents, and business segments. The site includes an electronics forum, technical library, industry directory, equipment auctions, videos, training courses, and other resources.

How to use this resource:

Although the SMTnet site alone is a great source that includes unique information, we particularly love the SMTnet Express Newsletter. This condensed yet information-packed weekly newsletter includes topical technical articles, forum highlights, equipment purchase and sale updates, upcoming events, and available training courses, with the latest job openings to boot.

Feb 3 edition of the SMTNet Express Newsletter

5. Global SMT & Packaging (Link)

Global SMT & Packaging provides a variety of articles, news, and expert commentary on advanced packaging-related assembly and surface mount of PCBAs. The variety of content formats available is what makes this website stand out. You can find podcasts, “Tech Talk Thursday programs,” expert panel debates, newsletters, webinars, and programs.

How to use this resource:

Covid has suspended our ability to participate in as many conferences and trade shows as we used to, so we use this site to stay connected by watching webinars, listening to the panel discussions, and tuning into the Tech Talk Thursday programs.

6. Economist (Link)

If you are searching for current affairs on electronics from a trustworthy news source, we recommend The Economist. The Economist is known for strict copyediting, rigorous fact-checking, and minimal reporting bias. It makes an excellent go-to if you want just the news with minimal sensationalism or subjectivity.

How to use this resource:

To use The Economist to find electronic news, use the search function, using “electronics” as a keyword. You can sort by date, ensuring you can find the most topical news events quickly.

The Economist search function, along with the latest news articles about electronics.

7. EMSNOW

EMSNOW provides the Electronic Manufacturing Sector, associated suppliers, and customer basis with real-time information and analysis covering the industry's global aspects. Along with videos, features, podcasts, and “Coming Events,” you can find columns here as well, and much of the information has been published yesterday or today.

How to Use this Resource:

EMSNOW is a go-to for the most up-to-date information. While we love weekly and monthly publications, we recognize that having new information is important and sometimes critical before making certain business decisions. We recommend checking in with EMSNOW once or twice weekly to stay updated on current news and analysis.

A Sample Analysis Column from EMSNOW

8. Electronics Sourcing (Link)

Electronics Sourcing is a magazine for purchasing professionals within the electronics distribution & manufacturing sector who buy, distribute, and sell electronic components and associated products. You can head to the website to sign up for the magazine and find relevant market news and magazines targeted to the UK & Ireland, North America, or Europe, which is a nice touch.

How to use this resource:

Although we love the content, the purchasing tools tab on the website menu bar is especially valuable. Here you can find Buyers’ guides for the UK & Ireland, North America and Europe, search or components, and component sourcing information.

Screengrab of the Latest News Section of the Homepage

9. ASSEMBLY Magazine (Link)

ASSEMBLY Magazine provides information on processes, strategies, and technologies for assembling parts in appliances, medical, automotive, and aerospace industries. You can find the Assembly eMagazine, podcasts, how-to guides, ebooks, webinars, and more here. The site offers a newsletter you can sign up for to quickly avail yourself of their latest resources regularly from your inbox.

How to use this resource:

Our favorite feature on this site is the ASSEMBLY InfoCenters section that you can access from the menu bar. One InfoCenter is dedicated to sensing solutions, for example, and it includes application stories, sensing insights, upcoming events, and a summary of relevant products.

Example of an ASSEMBLY Magazine Column

10. U.S. Tech (Link)

U.S. Tech has been distributing breaking news about electronics production since 1985. The website features a Daily News Archive, videos, white papers, a “Tech Watch” column, and an industry calendar, among other helpful information.

How to use this resource:

We recommend you sign up for the printed newsletter, published nine times yearly. Each addition offers a different view of the current state of electronics manufacturing from various technical perspectives.

Tech Watch Article

Wrapping Up

We hope this list was helpful and can be used to save some of your time. Please don’t forget us either! We provide Parylene conformal coatings and nanocoatings and discuss our technology, electronic reliability, design, industry news, and the business implications of sound engineering design on our blog and social media channels.

ADAS Design and Validation for the Real World - Automotive Coatings

June 15, 2023 / by Mallory McGuinness-Hickey posted in Parylene, Coating Properties, Thin Film Applications

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Advanced driver assistance systems (ADAS) continue to expand in features and functionalities. Standard offerings may include adaptive cruise control, park assist, blind-spot detection, lane departure, RADAR, emergency braking, tire pressure monitoring, and LiDAR systems.

When consumers purchase a vehicle with ADAS safety features, they believe they have a layer of protection to be entirely relied on. In reality, though, without a methodical, effective ADAS component design that accounts for real-life situations, these features are no more than crutches.

In addition to the ethical argument that safety should be an underlying principle of ADAS design, liability concerns create a business case for ADAS components that dependably function in the typical automotive service environment.

As ADAS designers evaluate the risk of harm, they may ask about the probability of exposure to an element or situation that could cause failure. They may ascertain how severe the resulting damage may be and determine how controllable the issue is if it should occur.

The risk of harm is high in instances such as premature ADAS component failure due to harsh environments. ADAS PCBAs and components will inevitably encounter corrosive elements, humidity, thermal shock, water ingress, and other environmental factors that compromise electronics. If this ADAS component should fail as a result, consumers relying on a safety feature could incur severe damage and liability, and in terms of controllability, there is not much that can be done upon critical component failure.

ADAS component reliability through harsh environments is a high-risk issue. Therefore, design engineers must prioritize safeguarding ADAS components from failing in these circumstances and verifying their safety in real-life situations. Testing and validation can become problematic when legacy methods such as gaskets and seals bolster ADAS reliability.

Possible Issues with ADAS Testing Protocols and Traditional Reliability Methods

Issues with ADAS reliability testing protocols may include:

● Testing must confirm that a system will handle situations that can be predicted and that ADAS will reliably work under unknown circumstances.
● Proper validation and verification can entail testing many conditions, particularly as vehicle design shifts towards fully autonomous vehicles.
● Testing for scenarios on a test track may be impractical when methods such as seals and gaskets are used for ADAS reliability.

For example, to test that a seal will continue to prevent ingress while exposed to vibration, you might have to wait for weather conditions to occur naturally, including snow, rain, or humidity. Although you can use equipment to mimic these weather conditions, this will add to testing complexity.

It's Possible to Simplify ADAS Reliability

As noted, seals and gaskets can become dislodged in many situations, which would have to be recreated and accounted for to validate and verify ADAS component reliability if they are the primary protection method. This unpredictability raises complications during the design and validation process.

Furthermore, as more features are built into vehicles, more components will need to fit in. The bulk of seals, potting, and traditional conformal coatings can lead to more design challenges. These conventional methods can also complicate lightweighting efforts as they add unnecessary weight.

HZO’s proven, trusted Parylene coatings solve these testing and design challenges. These conformal coatings come in several types, including Parylene N, Parylene F (VT-4), and Parylene C, demonstrating excellent performance in mission-critical applications for decades, in part due to uniform coverage, barrier properties, and less stress on mechanical structures.

HZO Coatings for Automotive Corrosion Protection

We’ve proven that our coatings can deliver as much – or more – flexibility, fungus resistance, flammability, dielectric withstanding voltage, thermal shock, moisture, and insulation resistance at a fraction of the mass of conventional coatings, passing the IPC CC-830C test at 50% of the film thinness. Unlike seals and gaskets, Parylene does not stop providing protection when exposed to unpredictable situations, such as drops and falls. The coating is well studied and, when appropriately applied by engineers who understand the parameters of an application, will withstand the lifecycle of the product it is enabling.

Class	Type	Specimen – Average Coating Thickness [μm]
		1	2	3	4
XY	Parylene N	25	25	23	23
XY	Parylene C	31	30	30	32
XY	Parylene F	46	36	43	29
AR/UR	Acrylic	73	73	69	72
SR	Silicone	102	99	114	154
AR/UR	Acrylated Polyurethane	91	91	107	107

Below, you can see how our coatings performed in automotive validation tests.

Contents	Requirements	Test Results
Operations Test	Operate for 24 hours at 23 Degrees C	Operate for 24 hours at 23 Degrees C
Coating Property	No Pinhole and Uncoated Area	No pin hole and uncoated area Coating thickness 225±3 [μm]
Electrical Test	Dielectric withstanding voltage: Over 1.5 [kV] Insulation resistance: Over 10 [GΩ] IPC-B-25A standard test board pattern Dv	Over 1.5 [Kv] Over 10 [GΩ]
Corrosion Test	Salt spray (35 °C, NACI, 96 hours): No corrosion on chip leads	No corrosion on chip leads

Enhanced Component Reliability and Increased Resistance to Fluids and Oils

The automotive operating environment includes exposure to chemicals such as oil, antifreeze, standing water, and cleaning fluids. HZO Parylene coatings offer dependable protection for various leak, environmental, splash, and submersion test requirements.

Protection Characteristics	Unprotected PCB	Mechanical Seal	Silicone/Acrylic Coatings	Parylene Coating
Protection Barrier	None	Good, but can be compromised with drops & temperature.	Good, but can be thick & porous depending on the application.	Excellent. Can peel if not properly applied.
Hydrophobic	No	No	Yes	Partial
Thickness	N.A.	Millimeters	μm – Millimeters	2μm – 50μm
Protection Against Water	Poor	Good – Ingress Poor – Penetration	Good	Excellent
Salt/Chemical Protection	Poor	Poor	Varies	Excellent
Durability	Low	Varies	Varies	High
Submersion Test Time to Failure	Seconds (IP Rating N.A.)	Varies	Varies	Days to Weeks (IPX7 – IPX8)

When used as a redundant solution along with legacy methods, our coatings can provide more robust, reliable protection and the ability to reduce sealing, thereby minimizing spacing and weight issues. As the visual below indicates, a mechanical seal can easily be breached. With HZO’s Parylene protection, moisture ingress is not an issue.

Contact HZO for Automotive Component Coatings

If you are interested in Parylene and would like to speak to our industry-leading applications engineering team, please reach out with a message or fill out a quote form to understand your application needs and provide a tailored solution.

IP Ratings Decoded: IP57, IPX7, IPX5 Explained

June 15, 2023 / by Ryan Moore posted in Protection Capabilities

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Download the IP Checklist

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Download HZO's Ingress Protection (IP) Checklist Your shiny new smartwatch claims to be IP57 waterproof, your new phone claims to be water protected, and a slew of new electronic devices are entering the market boasting 'water resistance.' Yet, these devices may not survive an encounter in the rain or an accidental drop in the toilet. So, how do you know what's what in the world of water-protected electronics?

Clever advertising and loosely applied water protection ratings have led consumers to believe that the stamp of an IP rating or a water-resistant buzzword means that the device in question can take a dip in the pool or, at the very least, hack it in the shower. But sadly, that's usually not the case.

So What's The Problem?

As manufacturers have tried to meet the growing consumer demand for water-resistant electronics, they have emphasized citing IP Code ratings. As beneficial as these ratings can be in certain situations, there is one major flaw: they don't tell the whole story. Here's the truth about IP and IP57 ratings.

What Does IP57 Really Mean?

An IP rating is a standard for water resistance in electronics. Water resistance is measured by numbers 1 through 9.

There are two types of IP ratings, which include two-digit IP ratings. Two-digit IP ratings indicate both water and particle resistance. The first digit displays particle and solid resistance, while the second digit shows the water protection level. If you own an electronic device with an IP rating of IP57, that device offers level 5 particle resistance and level 7 water protection.

One-digit IP ratings: Unlike two-digit ratings, one-digit IP ratings are metrics designed to show water resistance only, which means an 'X replaces the first digit.' For example, a rating of IPX7 would offer level 7 water protection out of 9 levels and is defined as can be submerged up to 1 meter in water for 30 minutes.

Is IPX7 Waterproof?

Well, that's kind of a long story. When a device claims to be waterproof or water-resistant, it's important to understand that these terms may not always carry the meaning you expect. Waterproof means impervious to water and all of the destruction that comes with it. Ultimately, it all depends on the manufacturer and the level of water resistance you're looking for.

Different IP ratings offer different types of protection, and you need to understand them if you want to grasp better whether your IPX5, IPX7, or IP57 device is genuinely waterproof. Following vague waterproof marketing terms can be challenging when you have little to no reference for what the actual numbers and ratings mean. Let's go through a few of the IP rating standard basics.

The water protection numbers exist on a scale of 1 to 9, while the solid protection metric operates on a scale from 1 to 6. Some of the most common numbers used to indicate high levels of water resistance are IPX5, IPX7, and IP57, each of which offers a different type of protection:

What is IPX5?

IPX5: An IPX5 rating implies that a device can endure direct contact with water that's projected from a nozzle. IPX7: IPX7 is one of the highest ratings, and ideally, it means that a device is durable enough to survive after being submerged in up to 3 feet of water for 30 minutes.

What is IP57?

IP57: IP57 indicates a high (though not the highest) protection level from dust and water exposure.

What is the Issue with IP Ratings?

The issue with these ratings is that it can be hard to tell whether they'll apply to real-world situations. To gain an IP certification, all an electronics manufacturer must send their device to a third-party laboratory to run the standard tests. If one (yes, just one) passes the test, the entire device line gets the determined IP certification. See the problem here? So, one tenacious device passes the IPX7 test, and the whole team gets to play as 'IPX7.' And with the sparkling new certification comes a heaping pile of consumer confusion.

"Does IPX7 mean waterproof?" "Does IP57 mean water-resistant?" "What can I actually do with my device?" When Traditional Ratings Fail To truly understand what your 'water-resistant device' is capable of, you need to read, and we might add, carefully read the manufacturer's terms and conditions.

Let's take a hypothetical, newly introduced 'waterproof' Android, for instance. The phone is advertised as "Waterproof*. Dust-tight. Worry-free." It also maintains an IP65 and IP68 rating. But what does the asterisk mean? If we look a little closer at the fine print, we find that the phone should never be put completely underwater or exposed to seawater, salt water, chlorinated water, or liquids such as drinks and juices. And if the ports and covers aren't firmly closed, all protection bets are off.

So What's The Answer?

HZO is seeking to detangle the web of confusion that is currently surrounding the 'waterproof electronics' market by offering a superior water protection solution. A solution without limits, boundaries, or fine print. Using Parylene conformal coatings, HZO creates a thin film barrier between the vital circuitry of the electronics and any liquid that could potentially harm it. No need for seals, gaskets, port covers, or cases, and in theory, no real need for confusing IP standards. We have had a computer running fully submerged in tapwater in our lobby for two years now. HZO Protection is the standard.

HZO-Coating-Raspberry-Pi-1

Superiority of Parylene Conformal Coatings

Parylene coatings are renowned for their uniform and pinhole-free coverage, even at thicknesses as low as a few micrometers. Parylene's chemical and physical properties provide outstanding resistance to moisture and contaminants, essential for electronic components in IP57 devices. Not only is Parylene's molecular structure optimal for creating a barrier against various types of ingress, but its application process ensures that it adheres without compromising performance. Its unparalleled durability, even in extreme conditions, underscores why, when it comes to device protection, Parylene conformal coatings are the preferred method for ensuring compliance with stringent protection standards like IP57.

If you're looking for a solution that can make your products more robust and, well, better, we're here to help. Our coatings can make a wide range of electronics more usable from almost any location, enhancing product reliability and—even better—saving money. Contact us today to learn more from a skilled professional about how we can help your product exceed IP57 and IPX7 ratings.

Preserving Power: Protective Coatings for EV Battery Corrosion

June 15, 2023 / by Ryan Moore posted in Thin Film Applications

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EV batteries promise to revolutionize transportation as we know it, but is it all positive? The future of electric vehicles is riding on the dependable operation of these energy storage vessels, so their reliability is vital. Unfortunately, like all mechanical and chemical processes, battery technology isn’t foolproof and is susceptible to failure, especially in the hazardous environments in which they perform. To better understand EV battery weaknesses and address them, it’s key to understand their origins and what steps are being taken today to safeguard against potential failure points, no matter the circumstance.

Check out HZO's Automotive Brochure

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How Old is the Electric Car?

The electric car is synonymous with the future of transportation. However, few may realize that its inception dates to 1881, four years before Karl Benz designed and built the first practical internal combustion vehicle. When consumers were polled in 1900 at the National Automobile Show in New York, the design was so popular that they voted electric vehicles the top choice over steam and combustion engines.

So why did the combustion engine ultimately win the race to mass adoption? Because of the same technical challenges facing EVs today: batteries. Early 20th-century battery technology was no match for the stored energy found in gasoline, nor could the average consumer purchase these primitive batteries due to price constraints.

EVs are Gaining Speed

However, in the early 21st century, battery technology has significantly improved, and the cost is within an affordable range. Finding solutions to these legacy problems has led to a staggering projected growth rate of 1,177% for EVs globally from 2020 to 2030.

Ensuring a Long Road Ahead

With this projected growth comes the compounding headache of ensuring the batteries operate reliably. Millions of drivers, commuters, and enthusiasts blindly rely on their vehicle’s battery to function as intended, no matter the driving conditions.

What are the potential points of failure in today’s batteries, including the rechargeable lithium-ion (Li-ion) batteries used to power EVs? Two natural threats can stop a battery, and therefore the vehicle it is powering, in its tracks: corrosion and strong electrical activity.

Corrosion: Corrosion is a common enemy to virtually all electronic components, and battery systems are no exception. This natural process occurs when a refined metal is converted to a more stable form, such as its hydroxide, sulfide, or oxide state, leading to the material’s deterioration.
Strong electrical activity: Strong electrical activity, including short-circuiting, can wreak havoc on EV battery technology. Where corrosion can be a slow killer, short-circuiting can instantly damage sensitive battery circuitry and components, potentially causing irreversible harm to the vehicle and its occupants.

These threats can be addressed safely and thoroughly through protective conformal coatings such as Parylene.

Protecting battery components with Parylene coatings

Corrosion and intense electrical activity can be prevented by properly coating susceptible components within the battery ecosystem. Parylene is a microns-thin conformal coating applied using chemical vapor deposition (CVD), a polymerization process unique to the material, responsible for its pinhole-free and truly conformal properties. Not only does Parylene provide a barrier against corrosive liquids to the parts it is applied to, but the material itself is a strong dielectric, capable of withstanding strong electrical activity. Parylene coatings provide ideal protection to EV battery components, including circuitry, busbars, and cold plates.

Download HZO’s Parylene datasheet

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Battery Circuitry: Every PCB is susceptible to corrosion when left to the elements. EV batteries exposed to typical automotive environments, including rainwater, salt, corrosive chemicals, and more, are no exception. Parylene coatings adhere tightly to the complex topography of a PCB, minimizing the risk of any exposure to corrosive liquids and gases.
Busbars: Busbars distribute power from high-energy battery packs to e-motors, e-axles, and other assemblies and components. If a battery busbar fails, power cannot be efficiently distributed to other vehicle functions, including the drivetrain or e-axles. The vehicle may also not be able to charge. For consistent operation, busbars require a dielectric coating, such as Parylene, with excellent adhesion, corrosion, and chemical resistance combined with mechanical, thermal, and electrical properties.
Cold Plates: Overheating can lead to thermal runaway if a cold plate fails, resulting in fires and explosions. Cold plates require protective coatings that strongly adhere to the substrate, can be used in operating temperatures from-40°C to +180°C, and provide excellent heat, oil, and moisture resistance to prevent overheating. These components also require a dielectric coating that protects against water, deionized water, Glycol and water solutions, and dielectric fluids. Parylene coatings can fill these needs.

Testing Parameters: Temperature – 35°C, Concentration – 5% NaCl by weight, Duration – 168 hours

HZO Parylene for EV Battery Component Protection

The electric car has come a long way since its advent in 1881, and we’re barreling towards mass adoption in the next ten years. It’s critical, however, that these vehicles perform as expected to preserve the precious cargo on board. EV batteries are susceptible to failure in the service environments they find themselves in and require proven protection while minimizing weight and cost.

Watch a webinar on improving electronic performance in harsh service environments

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It’s crucial for engineers and design teams to not only find a solution to ensure reliability on the road but find an application partner capable of applying the coating consistently and effectively. HZO has gone through the PPAP process, so you can be assured that we have met the associated manufacturability and quality standards laid out by our automotive customers. We have also demonstrated the aptitude to meet the necessary specification requirements and produce parts that consistently meet these requirements during the actual production of parts for these clients.

HZO has a unique ability to coat large, complex boards and components due to proprietary coating and automation equipment, handling parts in large qualities, and producing repeatable quality coatings with high yield rates. Our customer-focused solutions can be delivered with several flexible end-to-end business models as our team of dedicated engineers and SMEs walk clients through every step of the way of the coating process. Are you interested to see how we could help with your EV battery protection needs? Request a quote today.

Engineered Reliability: Conformal Coatings for ECUs

June 15, 2023 / by Richard Weiland posted in Thin Film Applications

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Quite possibly the most critical systems in modern-day vehicles, electronic control units (ECUs), are responsible for overseeing, regulating, and altering the operation of a car’s electronic system. ECUs control many aspects of the vehicle, including power steering, anti-lock braking, fuel injection, and interior cabin comfort through air conditioning or music from a favorite radio station. Most modern cars contain up to 80 ECUs, and these systems will continue to multiply with technological improvement and the introduction of new features. Each of these ECUs must integrate into the vehicle infrastructure.

Since ECUs facilitate features directly impacting vehicle operation and overall user safety, reliable operation is crucial to maintaining peak performance standards. One example is the engine control module (ECM), which regulates a series of actuators in a vehicle’s engine to ensure optimal performance. These units can control engine operation and management variables, including air-fuel ratio, idle speed, and ignition timing. If an ECM fails, the vehicle typically will not start. Consequently, these units are expected to perform for the vehicle’s lifetime – the EPA mandates that vehicle manufacturers warrant engine control modules for eight years / 80,000 miles.

Replacing these units is costly and can exceed over $1,500 in parts alone. Often, ECUs are placed throughout the vehicle and can be exposed to various stringent operating conditions, including environments with corrosion, moisture, vibration, and heat. The engine control module is located in the vehicle engine bay and is exposed to these harsh environmental conditions. Regardless of the type, protection of ECUs is imperative to ensure that these devices can reliably perform throughout the vehicle lifecycle despite regular exposure to undesirable settings. The most common threat to ECU reliability is highly corrosive environments produced by exposure to humidity or moisture.

Regardless of the type, protection of ECUs is imperative to ensure that these devices can reliably perform throughout the vehicle lifecycle, despite regular exposure to undesirable settings.

Seals or enclosures, typical protection methods for electrical control units, are designed to prevent moisture ingress but cannot provide further protection once moisture penetrates. Unfortunately, they become worn throughout operation due to stresses endured from heat, vibration, and general use, creating voids for moisture and humidity access that can lead to ECU damage and inoperability. In addition, these protection methodologies can create complexities and design limitations as ECU form factors continue to be optimized for vehicle size and fit.

Protection Characteristics	Unprotected PCB	Mechanical Seal	Silicone/Acrylic Coatings	Parylene Coating
Protection Barrier	None	Good, but can be compromised with drops & temperature.	Good, but can be thick & porous depending on the application.	Excellent. Can peel if not properly applied.
Hydrophobic	No	No	Yes	Partial
Thickness	N.A.	Millimeters	μm – Millimeters	2μm – 50μm
Protection Against Water	Poor	Good – Ingress Poor – Penetration	Good	Excellent
Salt/Chemical Protection	Poor	Poor	Varies	Excellent
Durability	Low	Varies	Varies	High
Submersion Test Time to Failure	Seconds (IP Rating N.A.)	Varies	Varies	Days to Weeks (IPX7 – IPX8)

Parylene Performance Characteristics Versus Competitor Solutions

On the other hand, conformal coatings (thin polymeric films applied directly to substrates and components) can be customized to the application environment, provide robust protection, and allow for lighter and smaller ECU assemblies. They may reduce the need for traditional seals or enclosures altogether. However, choosing a suitable conformal coating material is imperative because selected chemistries can directly impact ECU functionality and reliability. Traditionally, acrylics, epoxies, and silicones have protected printed circuit board assemblies (PCBAs) in ECUs from environmental contamination. Still, these materials require substantial layering and thickness to demonstrate protection benefits. And as electronics continue to miniaturize and increase in overall complexity, conformal coating weight and application footprint are essential variables to consider when evaluating protection alternatives to minimize bulk.

HZO’s Parylene coatings are a natural fit for ECU applications due to their demonstrated performance across various test parameters and application environments. Considered the gold standard, Parylene conformal coatings come in various types and have nearly 50 years of reliable, durable, and long-lasting performance across industries. The coating is superior in uniform coverage, barrier properties, and performance at comparably thinner films, with less stress on mechanical structures and virtually no added weight.

Class	Type	Specimen – Average Coating Thickness [μm]
		1	2	3	4
XY	Parylene N	25	25	23	23
XY	Parylene C	31	30	30	32
XY	Parylene F	46	36	43	29
AR/UR	Acrylic	73	73	69	72
SR	Silicone	102	99	114	154
AR/UR	Acrylated Polyurethane	91	91	107	107

HZO’s Parylene passed all IPC CC-830C at 50% of the Film Thickness of the Traditional Conformal Coatings

Unlike liquid conformal coating methods that may lead to coating defects, Parylene coatings are unique in their ability to be polymerized and deposited by vapor deposition onto substrates maintained at room temperature. The result is extremely thin, pinhole-free, high-purity coatings that fulfill the reliability requirements of automotive design. Parylene is highly conformal, offering the best protection also on corners & edges of components, creating a thin 3D-type film across the PCBA. The highly conformal and microns thin coating offers design flexibility & results in extremely low contact / interfacial resistance. These properties are due to the chemical vapor deposition (CVD) process specific to Parylene. Parylene is also unique due to its ability to be deposited in several chemical variants, demonstrating unique film performance characteristics.

Each Parylene composition offers exceptional salt, mist, moisture, dust, and environmental protection. However, some Parylene types exhibit performance qualities that excel in specific circumstances or application environments. Examples of these variants include Parylene C, which is the most effective conformal coating available for corrosion protection at its thickness. Parylene F exhibits superior thermal resistance and is ideal for maintaining protective performance while exposed to high heat.

Watch our webinar on proven methods of corrosion resistance

Polymer	Gas Permeability at 25 °C, (cc·mm)/(m2·day·atm)							WVTR,(g·mm)/(m2·day)
Polymer	N₂	O₂	CO₂	H₂	H₂S	SO₂	Cl₂	WVTR,(g·mm)/(m2·day)
Parylene C	0.4	2.8	3.0	43.3	5.1	4.3	0.1	0.08
Parylene N	3.0	15.4	84.3	212.6	313	745	29.2	0.59
Parylene D	1.8	12.6	5.1	–	0.6	1.9	0.2	0.09
Parylene F (VT-4)	–	16.7	–	–	–	–	–	0.28
Epoxy (ER)	1.6	4	3.1	43.3	–	–	–	0.94
Polyurethane (UR)	31.5	78.7	1,81	–	–	–	–	0.93
Silicone (SR)	–	19,685	118,110	17,717	–	–	–	–

Water vapor transmission rate and gas permeability indicate barrier effectiveness for corrosion resistance. The chart illustrates that Parylene C’s WTVR and permeability properties are exceptionally low. HZO-coated automotive assemblies were exposed to HAST (Highly Accelerated Temperature and Humidity Stress Test) at 130 °C and 90% RH for 48 hours while powered at 14 V and a sampling rate of 0.5 Hz. HZO coatings pass by, preventing any current spikes over 0.5 Amps.

Parylene F is best suited for operating temperatures in the -55 °C to 200 °C range, while Parylene C can be utilized from -55 °C to 85°C. Exposed to the HAST conditions described above, Parylene F films would best serve applications like ECMs found in the engine compartment and exposed to high-temperature environments. Parylene C is a better alternative for corrosion protection for ECUs in areas of the vehicle that do not have high-temperature considerations but need resistance to moisture, humidity, salt, or other chemical exposure.

HZO’s Parylene coatings can offer superior protection for automotive applications like ECUs and have demonstrated aptitude through various testing methodologies to meet necessary performance requirements and specifications. In addition, we have experience with the PPAP process to assure that production parts will be executed in a highly repeatable and quality-focused manufacturing environment. Our unique ability to handle large and complex parts due to proprietary coating and automation equipment with exceptionally high yield rates makes us well-suited to the automotive industry.

Meanwhile, HZO’s customer-focused solutions can be delivered with highly customizable end-to-end business models as our dedicated engineers and SMEs work with clients through every step of the coating process. If you have any questions about our automotive conformal coating services, contact us, or if you think we might be appropriate for your next project, request a quote today.

Parylene Conformal Coatings - Parylene Conformality Explained

June 6, 2023 / by Mallory McGuinness-Hickey posted in Parylene, Coating Properties

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Parylene (p-polyxylylene) conformal coatings are unique due to their capacity to be polymerized and deposited by the chemical vapor deposition (CVD) method onto surfaces near room temperature. As a result of this process, pinhole-free, high-purity, extremely thin coatings are formed out of dimer materials.

Regarding conforming to complex or unusual surfaces, Parylene is one of the best polymer coatings for moisture resistance. This attribute and the fact that Parylene is a stable chemical compound that creates an excellent barrier make it the optimal choice where resilient electronic products are a mandate. But why is Parylene coating conformal?

Download HZO’s Parylene datasheet to learn more about Parylene’s properties

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Why is Parylene Coating Conformal?

Liquid coatings with application methods such as dipping, brushing, or spraying may cause the coatings to exhibit meniscus forces or pull away from edges, which does not occur with Paylene deposition. With CVD, the coating penetrates around and beneath closely spaced components with consistent, uniform buildup, allowing for substantial physical and electrical protection with a substantially thinner layer than conventional coatings.

Parylene Deposition Process

Thus, the Parylene coating process explains why Parylene is so conformal. You can read an in-depth description of the CVD process versus PECVD in our blog on the subject; below are some general benefits of CVD:

Download a visual explanation of the process

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CVD produces coatings with complete coverage even around and beneath closely spaced chips and wires.
CVD deposits Parylene molecule by molecule onto substrates with precision and control.
The Parylene deposition process requires no catalyst, hardener, or heat curing.
Polymerization does not release harmful by-products, as with other conformal coatings.

Chemical vapor deposition process

When Parylene polymers are deposited from the vapor phase with the CVD process, all sides of a component are impinged by the gaseous monomer and uniformly coated. This feature of the process is responsible for why Parylene coating is conformal.

Importance of Conformality and Uniformity

Truly conformal coverage occurs when a film precisely follows the coated component’s geometry. Conformality allows for the optimization of surface properties regardless of the shape of the part and ensures that microdevice properties such as conductance do not vary due to significant variations in thickness. Uniform thickness is critical to prevent proper reinforcement against degradation and wear.

Parylene Conformality Compared to Liquid Coatings

Along with performance concerns, achieving uniformity improves production factors such as yield rates and repeatability. With the chemical vapor deposition process, engineers have confidence that there will not be thickness fluctuations from product to product and that specs are being met. By ensuring optimum coating deposition performance is met, you can lower your total cost of ownership by keeping your repeatability and yield on target.

Parylene Conformal Coating Service with HZO

However, although a process may achieve repeatable, uniform thickness distributions, this does not mean it is viable for your company – uptime and upfront costs must also be considered. Parylene has traditionally only been used for mission-critical applications such as medical products. HZO, a turnkey CVD process provider, has made Parylene and its application feasible for most industries for years. Our engineers have crafted capital coating equipment that addresses upfront cost concerns and makes Parylene scalable. If you are interested in the powerful barrier properties of Parylene films and the benefits of its vacuum deposition process, reach out today to speak to one of our engineers.

What is Parylene? Industry Use Cases, Types, Properties

June 6, 2023 / by Mallory McGuinness-Hickey posted in Parylene, Thin Film Applications, Value of Coatings

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What is Parylene? Is it Right For My Project?

Parylene forms high-performance thin-film coatings. There are several types, like Parylene N, C, and D. Each has unique chemical traits for different uses. Across all types, Parylene has excellent dielectric strength and unmatched barrier properties. The coatings resist corrosive gases, moisture, and solvents, ensuring product longevity.

Parylene coatings provide seamless coverage that is defect- and pinhole-free. The CVD process polymerizes and deposits them onto components at around room temperature. The coatings are free of defects and pinholes, which are ideal for critical applications where reliability and performance matter. Parylene is used in medical devices, aerospace parts, and advanced electronics for these reasons.

Why Do Engineers Use Parylene Coating?

Parylene is a unique conformal coating. Its properties give it superior performance in many applications. Parylene coating is recognized for its impressive dielectric properties, providing exceptional electrical insulation. It can work well in many electrical and electronic contexts, protecting against short circuits and other hazards.

Parylene also exhibits robust chemical resistance, preserving components in corrosive environments. Chemical agents find it hard to penetrate Parylene's molecular structure. This ensures the longevity and reliability of coated devices.

Another notable attribute is Parylene's moisture and vapor protection. Parylene forms a seamless barrier when applied, defending against water and moisture ingress. Preventing such contamination is vital to keeping components functional. This is especially true for those in high-humidity areas or subject to sudden temperature changes.

Then there is Parylene's thermal stability. Parylene's composition lets it withstand extreme temperatures. The coating keeps its physical and chemical properties across a wide range. Parylene can endure both the bitter cold of cryogenics and the intense heat of aerospace engines.

Parylene's versatility makes it more than just a protective coating. It is a strategic ally for industries where durability and performance are vital. Parylene-coated components work well. They are safe from environmental damage. Thus, using Parylene as a protective solution is not just a preference. It is a choice based on its proven ability to protect and preserve.

Download Datasheet

What Industries Use Parylene?

In electronics protection, Parylene is a shield against moisture and threats. The coating protects sensitive circuits from humidity, corrosive gases, and contaminants. Everyday devices, from smartphones to satellites, benefit from such defense. It ensures they work and last longer.

Why is Parylene Used in the Medical Industry?

Within the medical industry, Parylene's biocompatibility and chemical resistance make it indispensable. Parylene creates a barrier between the device and the body, making medical treatments safer and more reliable.

Download our medical brochure

Why is Parylene Used in Aerospace?

Parylene can make UAVs more lightweight, improving battery performance. Also, Parylene protects PCBs and components from humidity, weather hazards, and pollution.

Read about drone coatings

Why is Parylene used in the Automotive Industry?

Parylene improves the reliability of electronics exposed to high temperatures and abrasive conditions. Its chemical resistance helps automotive electronics withstand oils, cleaning fluids, and antifreeze. Parylene is also a green coating compliant with Prop 65, REACH, and RoHS.

Watch a video about why automotive OEMs use Parylene:

Why is Parylene used in LED Systems?

Parylene keeps LED brightness and color consistent over time and protects outside displays from weather damage. The thin coatings make it easier to mount displays as well.

Read an LED case study

Parylene for Military Applications

In the military, Parylene coatings protect advanced defense equipment. They ensure mission-critical applications remain reliable in tough conditions. Parylene meets the MIL-I-46058C specification.

Learn more about MIL-I-46058C

Why is Parylene Used for Consumer Electronics?

Parylene makes gadgets more durable. It helps them resist wear and tear from daily use. Consumer electronics manufacturers can use Parylene coatings to meet any IP rating.

Read a hearables use case

What Are the Parylene Types Used for?

Different applications need different Parylene types. Each has unique properties, suitable for various uses. Manufacturers might choose Parylene N for electronics needing a dielectric layer. Parylene C is better where moisture and gas ingress are concerned. Parylene D, though less popular, can withstand high temperatures Parylene N and C can't.

Parylene N

Parylene N can penetrate and coat minute spaces effectively. This feature creates coatings that can evenly cover complex shapes on electronic parts. Parylene N has no chlorine atoms in its molecular structure, and the coating has a high dielectric strength.

- High dielectric strength
- Excellent crevice penetration
- Good for delicate electrical components

Parylene C

Parylene C has a chlorine atom, altering its properties. This change gives Parylene C lower moisture and gas permeability. With enhanced barrier properties, Parylene C protects medical devices from bodily fluids and sterilization.

- Superior moisture and gas resistance
- Good for corrosion protection
- Often used for medical equipment

Parylene D

Also, we encounter Parylene D. It has two chlorine atoms in its structure. This constitution gives Parylene D greater thermal stability than Parylene N and C, useful in high-temperature applications. But, Parylene D is less commonly used than its counterparts. Its applications can be specific and rare.

- Greater thermal stability
- Good for high-temperature environments
- Narrower range of applications

Why Choose Parylene Over Other Conformal Coatings?

Parylene has distinct differences from other coatings like silicon and epoxy. Parylene's unique chemical vapor deposition process gives it a 100% conformal coating. This provides a strong barrier against moisture, chemicals, and extreme temperatures. This contrasts with silicone coatings. They are usually applied by brushing, dipping, or spraying. These methods can cause inconsistencies in coating thickness and performance.

Durability, too, distinguishes Parylene from other coatings. Parylene's strong molecular structure makes it durable under stress. This gives it a long lifespan. Meanwhile, epoxy coatings are strong but can become brittle over time. They also lack Parylene's ability to stay elastic and flexible in varying temperatures.

When you need ultra-thin, uniform coatings, Parylene is often best. It can coat at micron-level thicknesses without compromising coverage or protection. This lets manufacturers meet design specs without adding weight or changing dimensions. Also, Parylene's biocompatibility makes it vital for medical device coatings that will contact bodily tissues or fluids.

Silicone and epoxy coatings work well in many uses. But, they may not meet the strict standards in aerospace and medical industries. There, even the smallest failure can have catastrophic results. In such cases, choosing Parylene proves its unmatched performance in critical uses.

Bottom Line – Is Parylene Right for My Application?

Should you use Parylene for your next project? First, ask yourself how much you value reliability and performance. Then, answer the question.

Consider Parylene when failure is not an option.

Parylene may also be your best bet when you need lightweight protection. This includes aerospace and automotive markets that must support fuel efficiency.

Some products do not need such strong barrier properties and corrosion resistance. It's not necessary to ruggedize all devices. In these cases, it would raise costs, delay new products, and serve no purpose.

It is not always necessary to achieve critical, reliable protection. But when it is, Parylene coatings are the best defense. Have questions? Speak to an engineer.

Watch the webinar about Parylene’s proven corrosion resistance.

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Dielectric Constant of Insulator Materials: Formula, Table of Values

October 12, 2022 / by Mallory McGuinness-Hickey posted in Protection Capabilities

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Depending on their formulated ingredients and molecular structures, thin film coatings may be electrically conductive, insulative, or semiconductive. Insulative coatings serve several purposes, including providing dielectric strength to protect components exposed to high voltages and arc resistance. Dielectric constant (relative permittivity), the ability of plastics to store electrical energy, is another important electric function.

Read more about the dielectric strength formula.

Why is Dielectric Constant Important?

Knowing the dielectric constant is vital because lower and higher values are conducive to different applications.

For example, coatings with low values are preferred for high-frequency, high-speed circuits because they contribute little capacitance (ability to store electric charge). In these applications, high capacitance causes changes in component values and delays in switching times. The capacitance of a parallel plate capacitor is directly proportional to the dielectric constant of an insulator separating conductors and the area between the conductors. Therefore, capacitance can be reduced by using an insulator with a low value.

On the other hand, coatings with high dielectric constants and low dissipation factors make useful capacitors.

What is a Good Dielectric Constant for Insulating Coatings?

Dielectric constants for insulating coatings range from 2 to 8. Optimal electrical insulating coatings have low values and retain them over wide frequency, humidity, and temperature ranges.

The values arise from their electronic polarization abilities, and materials with low values include perfect vacuum, gases such as helium, nitrogen, and dry air.

The table below shows the dielectric constant of selected polymer conformal coatings.

Conformal Coating Type	Dielectric Constant (1MHz)	Desired
Parylene N	2.65	Low
Parylene C	2.95	Low
Acrylic	3.0- 4.0	Low
Epoxy	3.3 – 4.0	Low
Silicone	2.6 – 2.7	Low
Urethane	4.2 – 5.2	Low

How is it Calculated?

This constant ε is referred to as the dielectric constant or permittivity and is represented by the equation:

where Cm is the dielectric material’s capacitance and Cv is a vacuum’s capacitance.

ASTM D150 is a standard test method for measuring dielectric constants in which a sample is placed between two metallic plates of a measuring device. Capacitance is measured with the specimen in place and without. The ratio of these two measurements is the dielectric constant.

What Affects Values?

Values depend upon many factors, such as moisture content, frequency, and temperature. For example, the value will increase with increasing temperature at a constant frequency. Additionally, it may decrease or increase depending on variations in its composition. For instance, adding ceramic fillers with high dielectric constants will increase values.

Ultimately, it is important to gather accurate, reproducible data from testing that simulates the environment in which a component will operate to choose the best coating. Learn more about coating thin film coating properties such as volume resistivity and dissipation factor here.

What is the Dielectric Strength Formula? Testing, Table of Values

September 16, 2022 / by Mallory McGuinness-Hickey posted in Protection Capabilities

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Although thin film coatings serve many purposes, providing dielectric isolation and electrical insulation is one of the essential functions. Dielectric strength is an important electrical parameter that helps design engineers understand the effectiveness of a coating’s insulation resistance. It is helpful to be familiar with the exact electrical values for this property and to know how the values may be affected by environments, such as humidity and temperature, and purity, structure, and composition of the coating material.

What is Dielectric Strength, and Why is it Important?

Dielectric strength is a coating’s ability to endure an applied voltage without breakdown. This parameter is the highest voltage (typically stated in volts per mil thickness) at which no dielectric breakdown occurs. It quantifies how strong a conformal coating’s insulation is, with a higher number signifying the insulating material’s high resistance to dielectric breakdown.

Maintaining dielectric resistance is critical for impedance and signal integrity concerns, as the insulating material must keep the circuit working correctly. Enhancing dielectric strength protects the circuit board’s long-term function. The safety and effectiveness of a device with a circuit board rely on an entirely closed system, so insulation with high dielectric resistance is critical.

Additionally, PCB designs can be more compact when they feature a coating with increased dielectric strength. Integrating more capability into smaller form factors in the demanding electronics industry is crucial to staying ahead of the curve.

At both high and low voltages, dielectric considerations are particularly important for the reliability of electronic circuits.

Knowing the dielectric strength of a coating is critical for designing reliable electronics intended to operate at high voltages, as higher values represent a better insulator quality. If a coating is exposed to a voltage that causes breakdown, it will be rendered useless. Therefore, the data should be accurate – measured carefully to obtain reproducible results under specified conditions in a test.

Understand thin film properties in greater detail

Dielectric Strength Vs. Dielectric Breakdown Voltage Vs. Dielectric Constant – What is the Difference?

Dielectric breakdown voltage is the voltage threshold at which actual failure occurs. This value is also expressed in volts per mil thickness; these two terms are used interchangeably.

Dielectric strength and dielectric constant are both electrical properties. However, the former is the maximum voltage that can be applied to a material before it loses its insulating properties, and the dielectric constant is the capacity of a material to store electrical energy. These values are also expressed differently. Dielectric constant is a ratio with no units of measurement.

How is It Measured?

Several standard dielectric strength tests exist, including ASTM D149 and IPC-TM-650, Method 2.5.7. There are three basic procedures: the short-time method, the step-by-step method, and the slow rate-of-rise method. All these methods entail the same setup – a test specimen placed between two electrodes in oil or air.

In the short-time method, the most common test, voltage is applied across the two electrodes and raised to dielectric breakdown at a uniform rate. Breakdown is an electrical burn-through puncturing the specimen or decomposition in the sample.

Dielectric Strength Formula

With this test data, it is possible to calculate dielectric strength. The formula is to divide the breakdown voltage by the thickness of the sample. The value is reported in volts per mil thickness.

What Material Has High Dielectric Strength?

Organic coatings generally have much higher dielectric strength than inorganic or ceramic coatings. Materials that contain impurities, voids, and moisture will have lower breakdown voltages.

The table below shows the material dielectric strength of polymer conformal coatings.

Conformal Coating Type	Dielectric Strength	Desired
Parylene N	7000	High
Parylene C	5600	High
Acrylic	1200	High
Epoxy	900-1000	High
Silicone	1100-2000	High
Urethane	1400-3000	High

Source: Handbook of Plastics, Elastomers, and Composites, 4th Edition, McGraw Hill, Inc. New York, 2002. Chapter 6.

Why Do Insulating Coatings Break Down, and What Affects Dielectric Strength?

Even the most effective insulation materials contain a few free electrons and ions due to molecular imperfections or thermal agitation. The physical breakdown of the coatings is likely due to an electron “avalanche” effect (a large increase in electrons) within the coating. Several factors can affect this value. First, the thickness of the coating has an effect. Thinner coatings have higher values. A coating’s purity and physical integrity (lack of air void and pinholes) contribute to its effectiveness as an insulator. Dielectric strength decreases as impurities or imperfections increase. In terms of operating environments, exposure to moisture and elevated temperatures cause pronounced declines in values. In some instances, though, the final value is sufficiently high for most applications. To learn more about the electrical parameters of thin film coatings, read our protection capabilities page.

Arc Resistance - Concepts and Testing Explained

August 12, 2022 / by Mallory McGuinness-Hickey posted in Protection Capabilities

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Insulating materials such as Teflon, plastic, rubber, ceramic, or glass ensure products function properly and safely. However, no insulator is perfect. These materials still contain trace amounts of mobile charges that can carry current. Non-conductive polymeric coatings provide critical protection to electronic components, but these materials can become conductive when electric current travels along their surfaces due to chemical and thermal decomposition and material erosion. Therefore, the arc resistance electric property is considered when selecting materials where reliable insulation is a priority.

Arc Resistance Definition

Arc resistance is defined as the ability of an insulating material to withstand a high voltage, low current arc and resist the development of a conducting pathway along its surface. More specifically, it measures the time in seconds an electrical arc may exist on an insulator’s surface before the material’s breakdown occurs.

Arc resistance coating on a PCB

Significance

This property is helpful as a design criterion to choose materials for situations vulnerable to electric arcing but serves other purposes, acting as:

A quality control method
A way to screen materials for applications susceptible to arcing
Determining changes in insulation behavior due to aging, irradiation, exposure to temperature or humidity, chemical and thermal decomposition, contamination, and erosion

Arc Resistance Testing

The ASTM D495 test uses a high-voltage, low-current arc to simulate service conditions and evaluate dry, uncontaminated samples. According to the ASTM D945 arc resistance test, specimens are placed between electrodes, and an arc is generated at specified current densities and scheduled intervals. The total elapsed operation time until test failure determines a material’s arc resistance.

Several arc testers that comply with this test method are commercially available.

Test Methods ASTM D 2132, D 2303, and D 3638 entail wet testing with contaminated specimens.

How to Improve Arc Resistance

Differing molecular structures, formulation ingredients such as curing agents, and physical and chemical surface conditions cause arc resistances of coatings to vary widely. Fillers, such as glass or mineral fillers, can improve the arc resistance of polymer coatings, easily doubling or tripling the arc resistance of unfilled epoxy resin systems.

Additionally, resistance increases when the coating surface is kept dry and contaminant-free. Even touching the surface will reduce resistance due to moisture, oils, and salts transferred from the fingers.

Choosing The Right Coating

Not all coatings have exact arc resistance values due to issues with testing. Some crack, gum up, or melt during testing. When precise values that can be reproduced are acquired, they result from the material’s stability, purity, and surface cleanliness. If you need to evaluate material for a project, you can ask coating suppliers if an exact value is available.

Conformal Coating for Drones - Which is Best?

April 15, 2022 / by Mallory McGuinness-Hickey posted in Thin Film Applications

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As technology advances, so do the capabilities of drones, which are available in various sizes, weights, and shapes. The technological advancements in drone specifications, mapping software, cameras, and sensory applications are expanding how different markets use these remote-controlled flying devices, increasing their prevalence.

As such, there is a growing need to improve operational endurance in harsh weather conditions and enable longer missions in unpredictable environments, as sensors within the drones that measure atmospheric parameters and gas concentrations must safely and reliably function. For example, drones operating in underground mines must be waterproof, dustproof, and shockproof and resist pressure, temperature, and humidity. Conformal coatings can meet these requirements if applied and chosen correctly.

To choose which conformal coating is best as you design drones, you will need a thorough understanding of the application environment and associated electronic reliability challenges. You must also understand the properties of each conformal coating material to determine if these properties will meet your application requirements.

Although you may not plan on considering Parylene due to perceived challenges with scalability or cost, it may be the best conformal coating for your project. The film has long been used in the aerospace industry for its exceptional properties that significantly increase electronic reliability within aircraft.

Beneficial Parylene Coating Properties for Drones

Thinner and Lighter

The coating weight you choose can be critical to battery life, with lighter films increasing your drone’s lifespan. HZO Parylene coatings have passed IPC CC-830C tests at 50% thinness of other conformal coatings, proving the coatings can provide as much, if not more, insulation flexibility, flammability, thermal shock, dielectric withstanding voltage, and moisture resistance at a fraction of the weight and mass of alternatives.

Excellent Conformality, Pinhole, and Defect-free

Parylene coatings are ultra-thin, lightweight, and due to the chemical vapor deposition (CVD) application process, the thin films are highly conformal, wrapping around every edge available. The vapor deposition process is performed under vacuum, with specialized equipment, including a coating chamber. As a result, all surfaces are coated evenly with the same thickness all around the objects being coated. This vapor phase coating process also leads to pinhole-free coverage free from defects.

Download a drone brochure

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Beneficial Parylene Conformal Coating Barrier Properties for Drones

As aircraft that need to withstand more extreme temperature and pressure conditions encountered in aerospace applications, drones can benefit from Parylene’s impressive barrier properties, particularly those that protect electronics from the repercussions of corrosion.

Water vapor transmission rate (WVTR) and gas permeability indicate barrier effectiveness for corrosion resistance. The chart illustrates that Parylene C’s WVTR and gas permeability properties are remarkably low.

Table: Barrier Properties of Conformal Coatings

Polymer	Gas Permeability at 25 °C, (cc·mm)/(m²·day·atm)							WVTR,(g·mm)/(m²·day)
Polymer	N₂	O₂	CO₂	H₂	H₂S	SO₂	CI₂	WVTR,(g·mm)/(m²·day)
Parylene C	0.4	2.8	3.0	43.3	5.1	4.3	0.1	0.08
Parylene N	3.0	15.4	84.3	212.6	313	745	29.2	0.59
Parylene F (VT-4)	–	16.7	–	–	–	–	–	0.28
Epoxy (ER)	1.6	4	3.1	43.3	–	–	–	0.94
Polyurethane (UR)	31.5	78.7	1,181	–	–	–	–	0.93
Silicone (SR)	–	19,685	118,110	17,710	–	–	–	–

Download the HZO Parylene datasheet to find out more about Parylene Properties

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Read an in-depth discussion of Parylene properties here

HZO Parylene Conformal Coatings for Drones

Although Parylene’s coating properties present an ideal solution to drone reliability design challenges, it has historically been used in mission-critical scenarios, such as military applications or medical implants. However, as drones become more capable and critical across markets, can you afford to compromise on your conformal coating?

Learn about all of our thin film application areas, including medical device coatings, IoT, consumer electronics, automotive coatings, and industrial coatings.

HZO is a coating supplier that makes Parylene more scalable and cost-efficient through proprietary equipment and processes. If you desire the level of reliability that Parylene can provide but are unsure if it will fit within your budget or business model, please reach out to speak to one of our Applications Engineers. Our team can evaluate your project, determine if Parylene is a suitable solution, and advise how to move forward.

Parylene Masking - General Concepts Explained

January 28, 2022 / by Mallory McGuinness-Hickey posted in Parylene, Coating Process

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Conformal coatings are an excellent way to increase the reliability of electronic components in harsh environments. However, this protection can be too much of a good thing without processes to ensure certain areas remain coating-free.

These polymeric films can inhibit the critical functions of specific functions, but the masking process resolves this issue. With proper masking, you can benefit from conformal coating protection without losing functionality.

What is Masking?

Masking is applying a temporary film, boot, tape, or plug to designated assembly components to prevent them from being coated. While masking is important for conventional coatings such as acrylics, epoxies, urethanes, and silicones, Parylene has unique qualities that create a critical need to ensure it is done right.

Quick Introduction to Parylene Masking Techniques

For general guidance on conformal coating masking, the IPC-HDBK-830A handbook provides a good reference. However, because the coating process causes Parylene molecules to penetrate any surface area accessible to air, operators must ensure that all coating keep-out areas resist Parylene coating application, which requires domain expertise.

HZO uses proprietary masking equipment, and our engineers build and customize techniques for every project. However, a short description of general methods follows below.

Parylene masking techniques typically involve precisely sizing materials such as tapes, form-in-place gaskets, and boots to designated masked regions. After applying materials to the appropriate areas, a masking operator will allow peelable masking materials to dry before starting the CVD process, coating the entire component. After coating, the masking material is carefully removed.

Why Proper Masking for Parylene Coating is So Critical

Parylene’s exceptionally high dielectric strength requires you to mask the right areas diligently. A PCBA coated with Parylene would benefit from electrical insulation protection. However, if the connectors on that same PCBA get covered, you won’t be able to plug it in or make connections.

Another reason you must get your Parylene masking process correct is the film's incredible conformality. Where Parylene is allowed to penetrate, pins and moving parts will be completely encapsulated. Although this cohesive and thorough presence of coating is typically considered a benefit, additional cost and labor to remove the Parylene from the keep-out areas will be required with incorrect masking implementation. In other words, it’s best to prevent instead of rework, which can be challenging due to Parylene’s strong chemical resistance properties.

Why It Can Also Be More Complicated

When you mask for Parylene application, the stakes are higher. Once it’s on, removing the coating will be a struggle without a knowledgeable partner with tools and techniques to make rework easier. The fact that masking for Parylene is also more complex, requiring more skill, raises further complications.

Without skill and experience, masking for Parylene is more challenging than general conformal coating masking due to the chemical vapor deposition process (CVD) used to apply the coating.

Learn about Parylene Thickness

Unlike conventional conformal coatings applied as liquids, Parylene is applied as a vapor, which means you are masking against a gas. Therefore, a much better barrier is required with the Parylene masking process, as vapor can more easily bypass masking materials.

Other masking considerations include:

The need to validate if all components are hermetically sealed or not due to the vacuum nature of the CVD process
Chamber maintenance
Masking more than just keep-out locations may be required
The need for specific fixturing
Materials need to be thoroughly cured before coating, and outgassing should be avoided

The list below includes components that, in many cases, should not be coated:

MEMs
Actuators
Mating connectors and pins
Test points needed before assembly
Ground contacts

Parylene Coating With HZO

If you are masking for Parylene, you must implement the process correctly. Further, Parylene masking requires considerable expertise and experience to identify factors affecting masking success. These might include Parylene masking materials, the Parylene type, and the different areas that must be coated. Proper timing is also essential, as there is a relationship between the masking and coating processes. Any timing issues can impede coating quality. Managing electrostatic discharge is also a concern when masking.

Fortunately, our engineers have years of this experience, creating custom masking plans for customers with electronic products of all sizes, shapes, and functions. We have also developed industry-leading masking equipment that can automate and semi-automate the process for larger productions.

Reach out today if you would like a consultation to discuss why to use Parylene, our scalable Parylene coating equipment, or our automated masking processes that decrease Parylene coating costs.

How to Make Your Lithium-ion Battery Design More Sustainable

December 4, 2021 / by Mallory McGuinness-Hickey posted in Thin Film Applications

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A recent report from “Markets and Markets” revealed that experts expect the battery recycling market to grow to $23.2 billion by 2025, at a CAGR of 6.1% from 2020-2025.

This market focused on recycling batteries encompasses many industries and various battery chemistries, including lead-acid batteries, lithium-ion (Li-ion) batteries, and nickel-based batteries. The impetus for this market growth includes sustainability regulations that strive to preserve resources, reduce carbon footprint, and restore soil integrity.

Although data indicate a demand for responsible afterlife handling of batteries, complications can arise for Li-ion energy sources, raising concerns for product designers.

Lithium-ion Battery Disposal and Recycling Issues

Manufacturers value Li-ion batteries for benefits such as low self-discharge, low “memory” (the tendency to acquire a minimum or maximum state of charge), and high energy density. However, they have volatile chemistry that requires regulating their disposal on both state and federal levels.

Processes used to recycle lithium-ion batteries have merit because they can regain valuable metals from spent battery cells, including nickel, cobalt, copper, and aluminum. However, there are dangers associated with recycling processes, including thermal, chemical, and electrical hazards due to the potential for chemical reactions.

Designing Longer-Lasting Li-ion Batteries Can Be Part of the Solution

While no definitive, universally accepted solution exists to make lithium-ion batteries easier to handle after they no longer work, product designers can use Parylene coatings to prevent premature failure and encourage Li-ion resiliency despite exposure to failure-inducing situations. With the ability to extend product life and discourage unnecessary loss using a sustainable coating solution, you can do your part to comply with sustainability guidelines and reduce waste.

Download HZO’s Battery Coating Brochure

Download Brochure

How Parylene Reduces Unnecessary Lithium-ion Waste

Corrosion Resistance for Li-ion Batteries

A Parylene provider can strategically coat critical components of Li-ion batteries without interfering with their operation. The thin coating can act as a barrier layer, hindering the devastating consequences of corrosion and premature failure caused by corrosive environments.

Watch our webinar on proven methods of corrosion resistance.

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Parylene is particularly effective at protecting Li-ion batteries from corrosion. Its water vapor transmission rate (WVTR) and gas permeability, which indicate barrier effectiveness for corrosion resistance, are particularly low.

Polymer	Gas Permeability at 25 °C, (cc·mm)/(m²·day·atm)							WVTR,(g·mm)/(m²·day)
Polymer	N₂	O₂	CO₂	H₂	H₂S	SO₂	CI₂	WVTR,(g·mm)/(m²·day)
Parylene C	0.4	2.8	3.0	43.3	5.1	4.3	0.1	0.08
Parylene N	3.0	15.4	84.3	212.6	313	745	29.2	0.59
Parylene F (VT-4)	–	16.7	–	–	–	–	–	0.28
Epoxy (ER)	1.6	4	3.1	43.3	–	–	–	0.94
Polyurethane (UR)	31.5	78.7	1,181	–	–	–	–	0.93
Silicone (SR)	–	19,685	118,110	17,710	–	–	–	–

Ref.: Licari, James J. Coating Materials for Electronic Applications – Polymers, Processes, Reliability, Testing. William Andrew Publishing, 2003 and various companies’ literature.

The images below indicate the appearance of coin cell batteries, one exposed to salt water testing, one representing an HZO-coated battery appearance.

Figure 1 – Uncoated coin Cell battery subjected to salt water testing

Figure 2 – Image of what an HZO Parylene coated battery subjected to saltwater testing would look like

Heat Dissipation Properties of Parylene

Although lithium-ion batteries require protection from corrosives, when coatings (such as conventional coatings that require more coating to attain a suitable protection level) are applied in thick layers, this can interfere with the heat transfer path, impeding heat dissipation. As thermal conduction is inversely proportional to thickness, integrating the thinnest possible coating solution can prevent overheating, a serious reliability challenge for Li-ion batteries. HZO Parylene can provide superior corrosion resistance at 50% film thinness of conventional conformal coatings, meeting protection and heat dissipation challenges.

Parylene Will Withstand the Life of the Lithium-ion Batteries It Protects

When Li-ion batteries are stored for a long time, they become more susceptible to damage as they are exposed to environments with harmful elements. HZO’s coatings can sustain through the product lifecycle, averting common battery e-waste issues.

Table 3: Lifetime of HZO coatings at different temperatures in air (with oxygen)

	60 °C	80 °C	135 °C	150 °C
Parylene C	~100 years	~20 years	~70 hours	~24 hours
Parylene N	~10 years	~1 years	~9 hours	~1 hour

HZO Coatings for Lithium-Ion Batteries

As a green manufacturer, HZO focuses on inherently sustainable solutions that comply with REACH, RoHS, and Prop 65 and eliminate cure time. With Parylene, there are:

No VOCs
No Solvents
No Catalysts
No Disposal Issues
No Pollution Threats

If you want to learn more about the manufacturing advantages of working with HZO, contact us today to speak with an engineer.

Improving CGM Electronics Designs with Medical Coatings

November 20, 2021 / by Mallory McGuinness-Hickey posted in Thin Film Applications

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A vital issue for continuous glucose monitor development is design and reliability engineering.

CGM systems, however, will encounter environments that can jeopardize electronics that enable functions, such as sensors, making validation of actual product use difficult. The human body will subject CGMs to perspiration and other bodily fluids, vibration, shock, and the potential for drops.

Additionally, regular use presents threats in varied environments as users always wear the products in various settings. CGM devices are more valued by people with diabetes when they enable ease of use. Using continuous glucose monitoring systems in showers, harsh weather conditions, swimming pools, and humid conditions is often a purchase contingency.

Therefore, the ability to operate reliably through frequent exposure to chemicals and corrosives, including airborne pollution, cleaning fluids, soap, and hygienic products, is a critical feature that, if underestimated, can increase product recalls, repairs, and warranty claims.

CGM technology has exponentially evolved, but it is up to product design teams to evaluate if they are genuinely validating actual product use. If you are a CGM product designer and feel your products are experiencing reliability issues, coating systems, particularly Parylene conformal coatings, may be worth investigating.

Watch our webinar “Design for Reliability.”

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Corrosion Resistance is a Mandate for CGM Reliability

CGMs, like all electronic devices, run on electricity and batteries. Without proper protection, one drop in the water can kick off the corrosion process, catalyzing unexpected, premature failure. Parylene’s superior corrosion resistance is one compelling reason to use this CGM coating.

Performing as a barrier to corrosion caused by moisture, biofluids, submersion, and cleaning fluids, Parylene minimizes the impact of factors that affect coating performance and lifetime, including the following:

● Low oxygen permeability for a protective polymer coating
● Minimal absorption of water
● Ionic permeability makes it difficult for salts to pass through the coating
● Parylene’s characteristic pinhole-free coatings

Gas permeability and Water Vapor Transmission rate indicate barrier effectiveness for corrosion resistance; the lower, the better. The chart below illustrates these properties compared to other conformal coatings.

Download HZO’s Parylene datasheet

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Polymer	Gas Permeability at 25 °C, (cc·mm)/(m²·day·atm)							WVTR,(g·mm)/(m²·day)
Polymer	N₂	O₂	CO₂	H₂	H₂S	SO₂	CI₂	WVTR,(g·mm)/(m²·day)
Parylene C	0.4	2.8	3.0	43.3	5.1	4.3	0.1	0.08
Parylene N	3.0	15.4	84.3	212.6	313	745	29.2	0.59
Parylene F (VT-4)	–	16.7	–	–	–	–	–	0.28
Epoxy (ER)	1.6	4	3.1	43.3	–	–	–	0.94
Polyurethane (UR)	31.5	78.7	1,181	–	–	–	–	0.93
Silicone (SR)	–	19,685	118,110	17,710	–	–	–	–

Ref.: Licari, James J. Coating Materials for Electronic Applications – Polymers, Processes, Reliability, Testing. William Andrew Publishing, 2003 and various companies’ literature.

Watch our webinar on proven methods of corrosion resistance.

Watch on Demand

Submersion Protection Enables You to Meet any Liquid Ingress Protection Standards

As CGM consumers often base purchase decisions on the ability to meet IP ratings, it might be necessary for your team to meet a particular IP standard. HZO Parylene coatings have been tested for over 1,000 hours of submersion, providing a proven method to meet any IP protection level quickly and conveniently.

Download the HZO IP checklist

Environmentally Friendly Solution with Green Manufacturing Support

Sustainability policies and regulations can have far-reaching effects on your decisions, ranging from material selection through the manufacturing process. The Parylene polymerization process simplifies sustainability, as there are none of the following complications that can inhibit compliance:

No VOCs
No Solvents
No Catalysts
No Disposal
No Pollution Threats

HZO’s Parylene coatings are:

RoHS Compliant
REACH Compliant
Prop 65 Compliant

As a green manufacturer, HZO’s support includes the following:

Material oversight
Corporate social responsibility
Green material usage
Preparation for repair, reuse, and recycling
Proactive chemical management
Responsible end-of-life management

Simplify Design With Parylene's Thinness

HZO Parylene passed IPC CC-830C at 50% thinness of conventional conformal coatings, proving no other coating can perform as well in terms of chemical, moisture, and biofluid barrier properties at its thinness.

Parylene can also provide dielectric barrier protection without signal transfer or loss. Furthermore, its low dielectric constant ensures minimal energy loss in RF signals, and the coating thinness ensures signal transmission integrity. The chart below illustrates suitable Parylene thickness for various applications:

Thickness(μm)	Relevant Standards	IP Protection Level
0.1 to 5	UT Type in IPC-CC-830C	IPX3/IPX4
5 to 12.5	UT Type in IPC-CC-830C	IPX4/IPX7
12.5 to 25	IPC-CC-830B	IPX7/IPX8

Choose HZO for CGM Coatings

With CGM experience, our engineering team knows how to create business-specific solutions that ensure your product will work in the real world. HZO has eliminated many barriers to Parylene on the manufacturing end by developing cost-cutting equipment that can quickly scale as your business grows. If you want to meet with our applications engineering team for a DFM consultation, reach out today.

How Much Does Parylene Coating Cost? - All Things Considered

October 15, 2021 / by Mallory McGuinness-Hickey posted in Parylene, Value of Coatings

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Parylene coatings are known for robust protection from liquids, corrosion, chemicals, and strong electrical activity at a fraction of the thickness of alternative coatings, such as acrylics, epoxies, silicones, and urethanes. Additionally, Parylene is biocompatible, with beneficial optical properties, and delivers superior protection at 50% thickness of conventional coatings, such as acrylic conformal coating or epoxy. But, Parylene dimer and labor can be costly. So, design teams may hesitate to use them for high-reliability protection.

Read about why engineers choose Parylene.

Is Cost-Efficient Parylene Possible?

Many see Parylene coating as hard and costly to apply despite its proven performance. So, many assume it is suitable only for extreme, mission-critical situations. These include military, medical, and aviation applications.

What Are Other Common Misconceptions About Parylene?

Reworking and removing Parylene is impossible
Parylene coating equipment is too expensive and complicated to use
Masking is too complex and time-consuming to bother with
CVD coatings (chemical vapor deposition) entail long batch times. This raises labor costs and lowers throughput

These assumptions are unfounded. But Parylene coating is the most costly of all conformal coating options. So, choose a partner who can work within your budget. They should also help you estimate potential costs.

How to Calculate the Cost of Parylene

HZO capital equipment being used to lower Parylene coating cost

At HZO, we have crafted processes and procedures to cut the costs of Parylene coating. Yet, three factors are pertinent to the price regardless of whom you work with.

Parylene Type Affects the Cost

Common varieties, such as Parylene C and Parylene N, are less costly in raw coating material known as Parylene dimer. “Specialty types,” such as Parylene-AF4, will cost more but enable better UV and heat resistance. Consult HZO, a Parylene coating service, to find the best Parylene type for your project.

Parylene Masking Influences Price

Masking can be more complex with Parylene coatings, resulting in increased labor. However, changing your product's design can reduce costs. It would make it easier to coat and mask. HZO has industry-leading automated and semi-automated masking and demasking equipment. Working with us simplifies the process and cuts costs.

Quantity and Size of Objects that Require Coating

With Parylene, the objects you need to coat are placed into a vacuum chamber as part of the chemical vapor deposition (CVD) coating process. Each coating run will have a fixed cost. But, you can optimize the number of components coated in each run to lower the coating cost per item. (Meanwhile, HZO has built proprietary coating equipment that can house more items at once per run than any other Parylene company. This minimizes costs per run.)

Other Critical Considerations When Evaluating Parylene’s Price

Aside from considering upfront costs, to accurately assess Parylene’s coating expense, you must consider the coating’s value in terms of performance to preserve product function over time. In other words, the total cost of ownership is a critical consideration – upfront coating expense cannot fully measure value over a product’s life cycle. Parylene’s superior conformality and protection capabilities dramatically reduce field failures, warranty costs, and downtimes.

When you take the long-term view, the productivity and warranty savings that Parylene provides over time can make it the most economical coating option. There are other savings to consider when evaluating the price of conformal coatings, such as manufacturing costs. Conventional coatings entail cure cycles, VOC emissions, toxic byproducts, flammability, waste disposal, and health concerns. Parylene does not raise these safety and sustainability concerns as an environmentally friendly process.

Finally, investing in Parylene, with its exceptional dielectric strength, chemical and moisture resistance, and stress-free encapsulation, can substantially reduce the TCO to ruggedize components compared to other options.

Want to ensure HZO Parylene meets your specifications?

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HZO Parylene Conformal Coating Services

If you want to evaluate Parylene coatings, contact our experts. They will provide a free DFM consultation.

PECVD vs CVD – Chemical Vapor Deposition Overview

May 7, 2021 / by Ryan Moore posted in Coating Process, PECVD Coatings

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Thin-film deposition is the dynamic process used for depositing thin-film coatings onto a substrate, part, or assembly. Deposition methods, in general, can be grouped into three categories – liquid coating deposition techniques, physical vapor deposition, and chemical vapor deposition. This article will focus on chemical vapor deposition and one of its variants, plasma-enhanced chemical vapor deposition (PECVD).

Download our white paper on choosing the correct coating methodology for your next project:

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Chemical Vapor Deposition Methods

Chemical vapor deposition (CVD) methods (including but not limited to CVD, PECVD, and atomic layer deposition, ALD) are done under vacuum, well below atmospheric pressure, as the process deposits layers of material molecule-by-molecule or atom-by-atom. With these techniques, thin-film layers can be deposited in the range of nanometers to sub-20-micron, compared to traditional deposition, which yields coatings at 50-500 microns.

No matter the method, vapor deposition produces coatings that alter the substrates’ electrical, mechanical, optical, thermal, and corrosion-resistance properties. The resulting dry coatings are durable and have reached optimal properties without curing at the end of the production cycle.

Below is an overview of the chemical vapor deposition process.

Overview of the Chemical Vapor Deposition Process

The CVD process deposits materials, including Parylene, in a vacuum chamber by vapor deposition polymerization. The item to be coated is exposed to one or more precursors, which decompose or react on the surface. In the instance of Parylene, a solid dimer is vaporized to gas. Before entering the deposition chamber, the gas travels through a pyrolysis chamber that cracks the dimer into two di-radical monomers. The monomers adsorb onto the substrate as a polymer.

Chemical vapor deposition is used to augment substrate surfaces in ways that traditional modification techniques cannot. Polymerization by CVD allows for thin coatings with properties such as lubricity, weather resistance, and hydrophobicity.

Chemical vapor deposition is a repeatable process that produces consistent coverage and reliable results. Applications include:

Automotive electronics and sensors
Smart home security devices
Consumer electronics, including smartphones, hearables, and wearables
HVAC sensors
Smart city utility meters
Biosensors

Many hybrid application techniques arise from CVD, evolving to modify the properties of fabricated thin films. Among these variants, PECVD is a method that can extend the applicability of the technique for reactive and inorganic materials, inert materials, and various precursors. This technique is discussed below.

Overview of the Plasma Enhanced Chemical Vapor Deposition Process

Plasma-enhanced chemical vapor deposition is a variant of CVD; however, it uses plasma energy instead of only thermal energy to deposit thin films. The plasma is typically created by radio frequency, direct current, or microwave discharge that energizes reactant gases, such as silane or oxygen, to form a plasma. The deposition equipment uses a mixture of ions, free electrons, radicals, excited atoms, and molecules to deposit thin-film coatings to the substrate. Parts in the chamber are bombarded with energetic ions (plasma) that form a thin-film layer on the surface made from metals, oxides, nitrides, and/or polymers (fluorocarbons, hydrocarbons, silicones).

PECVD-deposited films have excellent physical properties because they are uniform, highly cross-linked, and generally resistant to chemical and thermal changes. Plasma-applied polymers are extensively used in optical coating and dielectric films due to their lower cost and higher efficiency properties. Offering excellent control of material properties (stress, refractive index, hardness), PECVD also produces films used in the semiconductor industry for device encapsulation, surface passivation, and isolation of conductive layers.

Different film compositions can easily be adjusted to produce organic thin films on large substrates (glass and silicon) with varying chemical, thermal, optical, electrical, and mechanical properties. PECVD has also recently been used for many biological applications, including medical device protection, and is also used to avoid corrosion in optical and dielectric devices.

This nanocoating process can use various materials as coatings, including metals, oxides, or silicon, which may offer more flexibility than CVD. Applications include:

Fabrication of electronic devices to isolate multiple conductive layers, capacitors, and for surface passivation
Solar cells, semiconductor devices, and optically active device applications due to optical, mechanical, and electrical properties
Processing of printable electronic devices due to high process efficiency, large-scale patternability, lower cost, and environmentally friendly nature
SiN (silicon nitride) PECVD films are used for semiconductor applications due to higher capacitance density, breakdown voltage, and particle performance.
SiC (silicon carbide) PECVD films have demonstrated promise in developing high-temperature withstanding MEMs devices.

CVD Benefits

When used with Parylene, CVD brings many benefits to the table, including:

Ultimate thin-film barrier material for liquid water, water vapor, and harsh chemical corrosion (acid, alkali, organic reagents)
Excellent dielectric strength to provide dielectric and insulative protection across an extensive range of frequencies
Highly conformal and adherent to many surfaces (metals, glasses, plastics, silicon, ceramics)
Entirely non-toxic (safe for all human contact, including implantable devices) and green (non-hazardous processing)

Download our introductory guide to protective coatings

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CVD Drawbacks

In comparison with PECVD, CVD can have the following drawbacks:

Higher cost: long deposition time (10-20 hrs) need for masking/demasking (80%-line cost), and high precursor (dimer) cost
Relatively thick film (typically 10µm minimum thickness needed for high integrity pinhole-free conformal coating)
Limited operating range/life due to the aging effects of heat (>50°C), oxygen (air), and UV (sunlight) exposure
Low wear resistance and mechanical durability limits use on exterior surfaces (cases, enclosures)

PECVD Benefits

PECVD offers the following benefits:

Ability to create “nano”-thin barrier films (50nm+) with low stress (room temperature process)
Lower cost: due to fast deposition times (accelerated by RF field) and relatively low cost/low use precursor materials
No need for masking/demasking to prevent coating on non-target part areas: the coating may be shielded using the part-holders
High tailorability: recipe changes facilitate diverse coating properties, including hydrophobic surfaces, UV protection, oxygen resistance, reworkability, and more

PECVD Drawbacks

In comparison with CVD, PECVD can have the following drawbacks:

Barrier performance is weaker than Parylene and highly dependent on the film thickness, layer count, and plasma type.
Limited wear resistance: materials are typically soft (enables rework but exacerbates handling issues).
Some coatings may be halogenated, raising health and environmental concerns.

Although this article has provided an overview of CVD and PECVD, it is only a high-level discussion. Chemical vapor deposition processes are a good choice for thin-film deposition, but selecting the proper method takes significant experience and technical acumen from a domain expert. HZO offers highly customizable protection solutions with both CVD and PECVD processes. If you have difficulty deciding which thin-film deposition method to use, contact us today to consult with our engineers.

NEMA vs IP Ratings Explained

April 14, 2021 / by Mallory McGuinness-Hickey posted in Protection Capabilities, Coating Properties

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Once upon a time, computers only sat perched on desktops, but that is no longer the case. Deployed in harsh industrial, medical, automotive, and consumer household environments, electronics must now withstand exposure to water and liquids ranging from “condensing” moisture to total submersion that requires waterproof design. They must reliably operate despite threats posed by humidity, corrosives, and other outdoor contaminants.

Learn more about protection capabilities such as water vapor transmission rate, dissipation factor, or volume resistivity.

To assure your customers that your electronic products can dependably withstand these challenges, you must meet reliability standards, such as Ingress Protection (IP) Standards or National Electrical Manufacturers Association (NEMA) Protection Ratings. These systems classify an enclosure’s protection level from harmful elements by defining protection posed by solids and liquid ingress. It is crucial to select the correct standard to assure your clientele that the product you offer will be reliable in specific environments. This choice can be complicated because comparing NEMA vs IP rating systems is impossible, but alternative solutions may eliminate the need to select one or the other.

View our webinar to see if it’s time to rethink enclosures.

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IP vs. NEMA-Rated Enclosures

Any comparison of Ingress Protection ratings and NEMA standards will only be approximate. An IP Rating only considers enclosure protection against water ingress and solid foreign objects. Meanwhile, the NEMA rating system, often used as an industrial enclosure rating system, considers these factors, as well as other hazards such as corrosion. So, while you can say a NEMA type is equivalent to an IP rating, it is impossible to say that an IP rating equals a NEMA rating. Additionally, the two systems use different test parameters to define the level of protection, so there is no easy conversion.

NEMA Ratings

NEMA electrical enclosure ratings have numeric values, sometimes followed by a letter. Each rating corresponds to the hazards an enclosure must protect its interior and may indicate indoor or outdoor use.

You can explore a quick guide to specific NEMA ratings.

When choosing a NEMA enclosure type, it’s essential to consider both the environmental hazards the interior needs protection from and the enclosure location to use NEMA ratings appropriately. For example, a NEMA 4 rating is popular because it accommodates outdoor environments and multiple weather types. NEMA rating 4X features watertight seals, corrosion resistance, and protection from dust for more extensive protection.

IP Ratings

IP ratings may be designated by two or three numbers corresponding to protection from solids, liquids, and impacts. X replaces the number if a device does not have a specific rating. The first number signifies the object size that the enclosure prevents from entering. The higher the value, the more protection from solid ingress, such as windblown dust.

The next value indicates liquid ingress protection, with digits ranging from zero to eight, with increasing amounts of protection as the numbers increase. Finally, the third value corresponds to the mechanical impact an enclosure can withstand. This value may not be present in some electronic products because most codes do not require its presence.

Read a short guide to IP ratings.

Read our IP Checklist

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Rethinking Enclosure Standards

IP or NEMA standards may not be the best indicator for the degree of protection you need. For example, while IP liquid ingress testing works in the lab, it may not perform the same in real life. Chances are that you will still need to demonstrate that your product can meet these standards to meet customer specifications.

Thin-film coatings can be an easy and efficient way to meet both NEMA and IP liquid ingress standards. These polymeric barriers protect from the inside by directly applying components and PCBAs. They are lightweight and thin, helping you eliminate seals and, therefore, excess bulk and weight. The protective coatings also blend into the product so you can offer aesthetically pleasing, ergonomic, and functional products easily. Thin-film coatings can be used in a two-phase approach to protection that is failsafe and can help you save money and time customizing enclosures.

HZO Coatings and Relevant Standard Equivalents

HZO offers thin-film coatings to protect your electronic products. We focus on tailored solutions to your protection requirements and can help you exceed liquid standards easily with proven solutions, with no enclosure testing required. Download our datasheets , or send us a message for a consultation.

How To: A Wearable Device Design That Consumers Actually Want

March 20, 2021 / by Mallory McGuinness-Hickey posted in Thin Film Applications, Value of Coatings, Resources

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Wearable devices provide insight and convenience to consumers through activity tracking and biometric data that they can easily access through a wearable app. But many wearable product designers have focused too much on producing functional devices without emphasizing the humans that wear them enough. This tendency could be to the detriment of user experience, limit user interaction, and make consumers less likely to purchase from your company again. Here are three quick tips on designing a wearable device that addresses human issues: discomfort and inconvenience, display issues, and lack of ruggedization for real-world usage.

1. Learn How to Make Wearable Technology Truly Wearable

Wearable tech can be challenging for design engineers because the body moves constantly, and humans want to move without constriction. Therefore, designing small, light, and comfortable wearables should be a priority.

For this reason, it is a good idea to begin the design process with a human factors and ergonomics analysis. This scientific discipline seeks to understand and optimize interactions among humans and systems to improve both system performance and the well-being of humans.

Consumers are likelier to wear devices with thinner, smaller, rounded form factors that lay flush on the body, applying minimal pressure. To ensure your product will be comfortable, test usability factors with real users and determine how easy and comfortable it is to move while wearing your product. Don’t forget to consider people’s different body sizes and types. For example, our customer Nike offered their FuelBand in several wristband sizes that the consumer would choose during the purchase process.

Finally, remember to design for every aspect of the use cycle, such as cleaning, bathing, showering, and leisure activities. Make an effort to be conscious of when and how humans clean their wearable devices so you can create a usable, convenient, easy-to-clean device consumers will want to use. Remember that users will not want to remove their devices during routine activities such as bathing and showering (and may not take off their wearables before swimming or entering a sauna), and accommodate this in your product design. The more convenient it is to use your product, the more consumers want it.

Watch our video series about designing reliable consumer electronics devices.

2. Consider the Display On-Device and What it Means for User Experience

To determine the right display for your wearable, ask yourself about the level of interaction required with the wearable. Wearables without display afford more design flexibility, are cheaper, and are simpler to produce. However, no available visual communication with the wearable will limit the level and scope of human interaction with it.

Minimal output displays portray selected information critical to the wearable experience. This type of display is one-directional, so the user can view it but cannot enter any input, limiting interaction. Another option is a full display, which allows for strong device interaction and a wider feature set. Determining which type of display is most appropriate for your users is an important decision that, unfortunately, may entail an aesthetics-functionality trade-off.

No matter which display you choose, you should expect and design wearables that will endure connectivity problems. Try to integrate some core functionality in your product’s offline mode when planning for your wearable UI. At a minimum, ensure the product explains what is happening to the user by incorporating wearable alerts when there is no internet connection to avoid confusion. If you choose a wearable with no display, this could be indicated through the mobile app.

3. Learn How to Design a Wearable Device for the Real World

Designing devices worn on the body can be complicated because they must reliably work in variable operating environments. In other words, they must go where humans go. Humidity, submersion, harsh weather, and corrosive exposure threaten wearable PCBAs. Don’t make the mistake of simply ensuring a device can pass reliability tests in the lab but not designed for the real world. Typically, consumers use Ingress Protection (IP) standards to guide their purchasing decisions, so achieving a certain level of water resistance is necessary.

Download our IP checklist.

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Conventionally, product designers have used seals to do this, but this method may not focus as much on user experience as it should. Humans frequently move, exposing these devices to vibration, which can dislodge seals and leave wearables unprotected from corrosion.

Another option is conformal coatings for wearable moisture resistance and corrosion protection. These polymeric films are applied directly to the circuitry as a barrier against many environmental threats. However, wearables have minimized form factors and require these coatings to apply thick layers, which may be too bulky and heavy, causing discomfort and inconvenience.

These legacy methods are often appropriate and do have their place. However, if you are placing more emphasis on users to improve your product experience, it might be worth considering Parylene conformal coatings. HZO’s Parylene can provide protection that meets or exceeds the corrosion protection of other conformal coatings at 50% thickness.

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The chart below describes Parylene thickness and the corresponding standards and IP protection levels they meet:

Table 1: Parylene Thickness, Relevant Standards, and IP Protection Levels

Thickness(μm)	Relevant Standards	IP Protection Level
0.1 to 5	UT Type in IPC-CC-830C	IPX3/IPX4
5 to 12.5	UT Type in IPC-CC-830C	IPX4/IPX7
12.5 to 25	IPC-CC-830B	IPX7/IPX8

Parylene Conformal Coatings for Wearables From HZO

As a proven method trusted for decades in mission-critical applications, Parylene eases many design headaches and addresses the user-focused issues above. As it provides robust protection at a fraction of the mass of legacy methods, you can make ruggedized wearables that are also truly wearable. Parylene’s superior chemical resistance properties allow your users to clean their products throughout the entire product life cycle safely. Additionally, using Parylene instead of seals can make it easy to design and produce wearables that meet finish, style, longevity, and reliability expectations, leading to consumer purchases.

It is possible to minimize offline disruptions because, unlike the other thick conformal coatings and seals, Parylene is applied in thin layers, facilitating RF signal transmittance.

When you work with HZO, our engineers will create a coating solution around your needs that easily fits into your production. From DFM services to QA, our team of experts will walk you through every step of the protection process, eliminating headaches and simplifying your process. If you want to discuss your project with our team, contact us today.

What is Corrosion & Does It Ruin Electronics? How to Remove It?

October 15, 2020 / by Mallory McGuinness-Hickey posted in Protection Capabilities

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Imagine the following scenario: You are washing the dishes, listening to music on your smartphone when suddenly the unthinkable happens – the phone that was nestled safely in your shirt pocket tumbles out and into a sink full of soapy water and dirty dishes. You manage to frantically retrieve your precious phone from its watery grave, dry it off, and find that somehow it is still working! It’s a miracle! You acted fast to save your phone, and you didn’t even need a bag of rice! All is well in the world of potentially water-damaged electronics… until two days later, when, for no apparent reason, your phone now doesn’t work, it short-circuited. Your miracle has turned into a nightmare. Water damage: 1. You: 0.

a phone dropped in water and being ruined by corrosion

The Meaning of Corrosion and What Causes It

We’ve discussed the science behind circuit board corrosion and how to prevent water damage with different conformal coatings, discussing why electronics and water don’t mix. One of the reasons we mentioned is the hidden and most puzzling cause of water damage: corrosion. Corrosion is the gradual breakdown of material, usually metal, by a chemical reaction with its environment. The most common form of corrosion occurs when you combine metal with water and oxygen, creating iron oxide (more commonly known as rust). This reaction occurs when you combine these elements for an extended period.

Does Corrosion Ruin Electronics?

There is no specific time frame in which deterioration happens; an electronic device can begin corroding a few hours after the initial water damage incident, or it can last days unaffected before showing any signs of a problem. How fast it sets in depends on humidity levels, the severity of the water damage, how long the device was submerged, and even how it is made. If the device was made to prevent water damage, exposing it to water won’t affect it. These factors significantly affect the time frame under consideration for a water-damaged device.

Learn More About Corrosion Protection

How to Remove Corrosion from Electronics

You must be very careful when cleaning up corroded electronics after water damage. You can damage the device further if you don’t know what you are doing, and you could also potentially injure yourself. Remember: devices and liquid generally don’t mix, so any time you apply cleaning solutions to a device, you must be cautious. The average consumer should never attempt to repair a device without professional assistance. The best rule to remember is to take it to a professional when in doubt! With that being said, here are a few helpful tips to keep in mind when dealing with deterioration and devices with water damage:

To clean a device post-water damage, always remove any batteries, power connectors, or power supplies first. This not only prevents harm to you but also prevents any short-circuiting to the device. Doing this will expose extra connectors that may already have corroded, so exercise caution.
Look for any white or green “crusty” areas on the device, especially on the battery connectors, charging ports, circuit boards, logic boards, SIM card connectors, or any other major metal connectors on the device.
Use cotton swabs and a cleaning solution such as isopropyl alcohol, baking soda, water, or even vinegar to clean it. Gently apply the solution to the affected area and wipe back and forth until the corrosion is removed. Leave some solution on the corroded area and wipe it off later.
Dry your electronic device with a soft cloth or a hair dryer in a cool setting – do not use heat to dry out your device. Ensure your device is dried extremely well before attempting to replace the battery and turn the device on. Any water left in the device could cause additional water damage.

Remember that whenever you are dealing with a water-damaged device, there is no guaranteed way to fix it once it has been subjected to water or already has deterioration issues. You can take steps to improve your chances of repairing it, but in the end, you have to cross your fingers and hope for the best.

If you want to learn more about waterproof electronic devices and the technology that goes into them, then visit our website! We provide protective coatings to eliminate corrosion from happening in the first place. Contact us today to waterproof your new electronic device, or dig deeper to learn how we protect electronics from corrosion.

IoT - Coating Consistency is Key

September 25, 2020 / by Mallory McGuinness-Hickey posted in Parylene, Coating Process, Coating Properties, Value of Coatings

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IoT sensors aggregate and send data to IoT dashboards, simplifying critical, complex decisions quickly. One key area where this is particularly true is the utilization of sensor data for predictive maintenance, a process that reduces downtime and lowers the total cost of ownership. Myriad other applications incorporate these “smart” sensors too.

Today, IoT sensors are ubiquitous, touching almost every aspect of life. Gas pressure sensors monitor pressure changes in oil, energy, and utility applications. Photoelectric devices (photo sensors) are now common in the consumer electronics vertical. Sensors are responsible for temperature monitoring, a typical use case for warehouse and inventory management, and HVAC systems monitoring.

Accelerometers detect subnormal industrial machine applications, while ultrasonic flow meters are coupled with IoT modules to send data about smart metering to a remote location. Moisture sensors have been critical in recent advances in smart farming, allowing for constant soil health monitoring. In the automotive sector, tunneling magnetoresistive sensors (TMR) are an increasingly popular way to measure mechanical displacement. And Particulate Matter sensors detect pollution in the industrial landscape and smart cities.

The chemical vapor deposition (CVD) process used to deposit Parylene conformal coatings can efficiently accommodate these complex surfaces. Parylene’s usefulness is primarily founded upon its ability to cover PCBA configurations with exposed internal surfaces, sharp edges, flat surfaces, points, and crevices with consistent coverage free of voids.

HZO PRO750 Parylene Coating Equipment

The Parylene Deposition Process – Consistent Coverage

Rather than dipping, spraying, or brushing pre-formulated layers onto PCBAs and other components, Parylene’s application method synthesizes the protective film in-process. This deposition system comprises a series of vacuum chambers that produce Parylene vapor, pyrolyze the vapor, then deposit the vapor as a polymer sequentially.

During the CVD process, gaseous Parylene penetrates the layers of a PCBA. Its vaporous consistency surrounds all areas as it builds coating protection along the exterior. The coating layers are substantially thinner than those provided by liquid conformal coating materials, enhancing reliability and functional versatility.

It has repeatedly been demonstrated that CVD is valuable for thin-film deposition on irregular PCBAs. CVD's Conformal layers are exceptionally uniform, even in the nanometer range. Because these coating layers are exceptionally thin, non-uniformity is minimal.

Reach out to an Expert

Choosing Parylene conformal coating services isn’t a failsafe decision, like anything else. Problems can occur with the process and the material. This is particularly true if the wrong Parylene type is used for a coating project while another type could provide better coverage. If you need a consultation to determine if Parylene is the right choice for your project, contact the HZO engineering team today, fill out a quote form, or leave a brief message.

Parylene Thickness - Industry Benchmarks, Cost, Effect on Properties

August 18, 2020 / by Mallory McGuinness-Hickey posted in Parylene, Coating Properties

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In the world of protective coatings, Parylene is a standout. Its unique, beneficial properties make it a great choice. Many Parylene types have distinct properties, like Parylene C, N, and F (VT-4 or AF-4, for example). By choosing a type, you can tailor Parylene to specific performance requirements.

How Does Parylene Thickness Affect Coating Properties?

The type of parylene dictates coating properties, while the thickness of the Parylene conformal coating determines its protection level. This includes electrical insulation, mechanical protection, and chemical resistance.

Electrical Insulation - A thicker coating usually has a higher dielectric strength. It can withstand greater electrical stress and prevent current leakage.

Mechanical Protection - Thicker coatings shield the substrate from damage, like abrasion better. They also resist mechanical stress.

Chemical Resistance - A thicker layer can delay the penetration of aggressive substances. It can also protect the substrate from corrosive environments for longer.

How Thick Does Parylene Need to Be?

How much Parylene do you need for your application? The answer depends on your design, choice of Parylene, and what environment you need protection from.

For example, applications requiring higher dielectric strength will require thicker Parylene layers, and this can be from 25 microns and above.

On the other hand, applications that are exposed to minimal moisture will typically require a coating greater than 2 microns.

What is the Best Parylene Thickness for My Industry? - Some Examples

Parylene Thickness Examples

Medical implants - Thickness varies depending on the use case and environment but typically can be seen in the 10 um to 20 um range.

Electronics - Thickness can vary from 2 microns up to and beyond 25um depending on the use case and environment of the product.

Aerospace components - A thicker application, often greater than 25 microns, offers enhanced protection from extreme environmental conditions.

How Thick Should Parylene Be in Different Environments?

Different environments demand specific barrier protection capabilities and, thus, different coating thicknesses. Analyze the threats in your application environment and the coating specs you must meet. Then, you can pinpoint the Parylene thickness you need. Here are some examples:

Moisture and Humidity - A Parylene coating as thin as2 microns can offer surface protection from moisture.

Submersion Protection: A Parylene coating from 5 microns and above will be able to protect most productions from freshwater submersion

Temperature and Humidity: Products that will experience a range of temperature and humidity changes over the lifetime of the product are typically coated at a thickness greater than 15 microns

Chemical and Solvent Resistance: Chemical exposure typically necessitates coatings over 10 microns to prevent permeation and ensure the integrity of the covered components.

Physical Abrasion: Parylene is a soft polymer and while it will not wipe off, it is not suitable to an environment where there will be continual abrasion of the coating.

By analyzing the environmental threats in your application environment and the coating specifications you must meet, you can pinpoint the Parylene thickness you need.

a coating expert double checking the parylene coating thickness on a PCB

How Do You Measure Parylene Thickness?

Coating thickness can be measured with various techniques. The industry standard method that HZO employes is to use spectral reflectance. This is done for every run in every one of our facilities. Additional methods such as contact Profilometry and Ellipsometry can also be used.

Spectral Reflectance

Spectral reflectance is used for measuring coating thickness by examining the interaction between light and matter at various wavelengths. Spectral reflectance measures how much light reflects from a thin coating over a range of wavelengths and is a non-destructive, non-contact method. Spectral reflectance is commonly used for coatings that range from around 1 to 50+ microns, most often on glass slide witness coupons and sometimes directly on a coated product with sufficiently flat and reflective surfaces.

Contact Profilometry

Contact Profilometry

With contact profilometry, a physical probe moves across the coating surface, registering variations in height to reveal thickness disparities. This mechanical method is respected for its accuracy and ability to produce detailed surface topography maps. However, the very contact nature of this technique might induce damage or introduce deformations to Parylene films, presenting a significant limitation so this Is not used on a a daily basis.

Ellipsometry

Ellipsometry, a non-destructive optical method, analyzes polarized light reflected from the coating surface. The ellipsometry tool infers film thickness by interpreting changes in the light's polarization state. Light interaction with the substrate complicates this analysis, often requiring the tool to perform complex calculations and it needs meticulous calibration to ensure accurate results, especially with non-uniform surfaces. Ellipsometry is more often used for sub-micron thickness coatings, especially on silicon wafer witness coupons.

At HZO, quality is top of mind. Since our inception, we've coated millions of components and haven't had one product return due to coating issues. Watch this video to learn more about our coating process.

Choose HZO as your Parylene Coating Partner

Are you wondering how thick the coating should be on your next project? No problem. Book a DFM consultation and speak to an engineer. They will tell you the next steps.

6 Common Conformal Coating Defects & Their Solutions

June 16, 2020 / by Mallory McGuinness-Hickey posted in Conformal Coatings, Coating Process

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When we say that a chain is only as strong as its weakest link, we aren’t talking about polymer chains – we’re talking about conformal coating defects. Regardless of the type, a single coating defect can affect the long-term reliability of a PCBA or component and must be repaired or removed. This can be costly and labor-intensive.

Therefore, it’s best to avoid defects from occurring in the first place. The following is a list of common defects and how to keep them from cropping up during your conformal coating application.

Learn how to remove conformal coating

The 6 Most Common Conformal Coating Defects and Solutions

Capillary Flow

Capillary flow, also known as scavenging, occurs when a conformal coating migrates from one area of a PCBA to another, leaving behind an inconsistent, uneven finish on the surface.

Common causes for capillary flow include:

The application of too much coating
Conformal coating with low viscosity or high surface tension
Low surface energy of component being coated

To avoid capillary flow from occurring:

Ensure that the PCBA is entirely clean before coating.
Use solvent-based coatings instead of water-based, and decrease the use of thinners to increase viscosity.
Before coating, heat the board to decrease dry time.

Learn more about epoxy conformal coating

Cracking and Ripples

Cracking and ripples can compromise a conformal coating film, exposing a substrate or PCBA to potential contaminants.

Common causes for cracks and ripples include:

Coating that is too thick
Thermal shock
Coating that has been cured too quickly

To avoid cracks and ripples:

Always apply the coating at an appropriate thickness.
Allow for extra drying time at room temperature.
Consider selecting a coating with a broader effective temperature range.

Dewetting

De-wetting is when a conformal coating will not evenly coat the surface to which it is being applied.

Many things cause dewetting, including:

An uneven coating application
An improper mixture of two-part materials
Residue on the coating surface
Variations in Surface Tension and Surface Energy

To avoid dewetting, thoroughly clean the material being coated before application.

Learn more about polyurethane conformal coating

a printed circuit board experiencing dewetting

Delamination

Delamination occurs when a coating has lifted away from the substrate. This hinders protection because the area below the coating is left exposed.

Delamination has many causes, including:

Too thick of a coating
Coating not adhering to the previous coating layer
Contamination on the coating surface prevented a good bond to the surface

To prevent delamination:

Reduce the thickness of the coating.
Thoroughly clean the substrate before coating.
Apply a “primer material” that can bond with the substrate and material used for conformal coating.

Orange Peel

Orange peel is when a coating appears dull, resembling the skin of an orange.

It is caused by conditions including:

A substrate that is too hot
Improper coating mixture or solvent ratio
A local environment that is too dry during application
A second coat has been applied before the first coat is dry

To avoid orange peel:

Apply coating at the specified thickness.
Reduce the viscosity of the coating.

Learn more about conformal coating vs potting

Air bubbles, Pinholes, and Foam

Bubbles occur when pockets of air get trapped under a conformal coating layer. Foam is an extreme form of bubbling, and sometimes bubbles burst through the conformal coating, forming a pinhole.

Bubbles, pinholes, and foam happen when:

A coating is too viscous
The coating is too thick
Application equipment has not been setup correctly

To avoid air bubbles, pinholes, and foam:

Use a lower viscosity conformal coating
Ensure the coating is applied at the recommended thickness.
When applying the coating, do so with thin coats.

Why This Doesn’t Happen at HZO

At HZO, we use a conformal coating application method called chemical vapor deposition (CVD) that circumvents these conformal coating issues. Using CVD, we produce uniform, pinhole-free conformal coatings every time. Contact us today to speak to an expert if you want to hear more about our proven technology and processes.

Conformal Coating vs Potting/Encapsulation - The Pros & Cons

June 11, 2020 / by Mallory McGuinness-Hickey posted in Conformal Coatings, Coating Process

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As the world of electronics continues to grow and evolve, printed circuit board assemblies (PCBAs) find their way into more and more products and industries. Whether you create products for consumers, the automotive industry, the military, or some other field, PCBAs play a big part in your product design. You’ll need to protect them without impeding the rest of your design.

You have a few options for coating a PCBA: conformal coatings or potting and encapsulation resins. These organic polymers provide chemical and thermal resistance and electrical insulation to the delicate PCBA beneath them. But that’s where most of their similarities end. This guide will discuss the differences between encapsulation resin and conformal coating and their effects on a PCBA.

What’s the Difference Between Conformal Coatings and Potting?

While both potting/encapsulation and conformal coatings protect a PCBA, they do so differently.

Electronic encapsulation seals a PCBA within a thick resin layer to protect substantially against physical shock, chemical exposure, and excellent electrical properties. Usually, this resin is dark-colored, so you won’t be able to see the board underneath it. The resin is mixed with a hardener before application, which allows it to cure a cross-linked polymer.

So, what is potting? While “encapsulation” and “potting” are used interchangeably, potting sometimes refers to the process used for PCBA encapsulation.

Alternatively, a conformal coating is a protective dielectric layer that is non-conductive. It protects from dangers like salt spray, fungus, moisture, and corrosion. The film, composed of epoxy conformal coating, acrylic, or silicone, is very thin and lightweight, having almost no dimensional effect on the PCBA or added stress to the components. Processing and applying this single-component material is easy and versatile, providing flexible options for the finished product.

While traditional coatings are single-component, some newer ones use a two-part process with polyurethane conformal coating to blend the protective aspects of PCBA potting with the flexibility of coatings. Plus, they don’t use solvents, which reduces concerns about volatile organic compounds (VOCs) present in many low-viscosity single-component coatings and adversely affects people and the environment. Fortunately, even those have come a long way, as most manufacturers have worked to reduce VOCs in their coatings.

Which Is Better to Protect My PCBA — Conformal Coating or Potting?

To best protect your PCBA, you’ll have to consider several factors of your product and how PCB resin coating and potting contribute to them.

Environmental factors play a significant role in choosing a protective material. Will your PCBA be exposed to any of the following?

Extremely high or low temperatures: You will have to consider the way resin can behave during use in extreme temperatures, how sudden or gradual the change is, and how heat could affect production. Resin generates a lot of heat when mixed with its hardener, which can cause damage to the PCBA or the housing if it gets too hot.
Water, humidity, or moisture: Some conformal coatings are less waterproof than others. While the resin is typically always waterproof, you’ll have to double-check that your coating is, too.
Physical shock: If your component might be exposed to heavy physical shock, the resin can help spread the impact across the material and reduce or eliminate the damage to the PCBA.
Mechanical stress: Abrasion and scratches can become problematic in environments like assembly lines and manufacturing equipment, where high speeds and volumes are typical. Resin provides a thick layer to protect against that physical threat.
Chemical exposure: If your PCBA could be exposed to harsh chemicals, both resin and coatings provide exceptional protection from exposure and submersion.

While PCBA potting offers more protective benefits, coatings hold the upper hand in design flexibility and can still protect products in everyday environments, like consumer electronics. Only those that are in particularly challenging environments typically need PCBA encapsulation.

a printed circuit board being encapsulated with a coating

Below are some design factors that factor into the debate:

Weight: Resin adds a thick block of material on top of the board, significantly increasing its weight. In many products, heavyweight components aren’t an option.
Thickness: Many products can’t function with the added thickness of the resin added to their design.
Workability: Since resin is dark and thick, you can’t see through it or easily remove it to rework the board. It could rip up the PCBA if you tried to take it off. Coating, on the other hand, is usually clear, which allows you to see through it and make adjustments if needed. This helps address any conformal coating defects.
Housing: If the housing of the PCBA doesn’t offer much protection, the resin may be a way to protect it more thoroughly. Coatings are often used as secondary protection within well-built housing.
Application: Depending on the design requirements, one option may be better for production. Resin can add risky heat during application and takes longer to cure. Conformal coatings tend to be quick-drying and can be applied in several ways, such as painting it with a brush, spraying it on, dipping the PCBA, and using robotic systems.

Conformal coatings are an excellent way to protect a PCBA from common threats without paying for the added weight and cost of encapsulation.

Here at HZO, we use a coating called Parylene, which is biocompatible — meaning it’s great for the medical devices industry — and extremely thin. It is clear and excellent for waterproofing and liquid protection.

Pros and Cons of Potting/Encapsulation

Designers often choose PCBA encapsulation for products in heavy-duty environments, as it protects against many damaging agents.

Some of the benefits of PCBA potting include the following:

Provides added protection against chemical, thermal, and physical risks, including water and shock.
Offers better performance for high-speed and high-volume work in industrial environments.
Has VOC-free options.

Some disadvantages of PCBA potting are:

It makes it difficult to inspect or rework the PCBA.
Causes possible design issues due to the added weight and thickness.
A more complex application process, especially regarding heat and two-part mixing.

Pros and Cons of Conformal Coating

Conformal coating is more popular than potting. It protects many consumer products outside dangerous exposure environments and provides more design flexibility. However, if your product is used in rough applications, it may not offer all the necessary protections.

Here are some of the pros of conformal coatings.

Thin and lightweight, offering superior design flexibility and no stressed components.
Offers protection from low-level issues like salt spray, dust, moisture, and corrosion.
Offers a variety of application methods.
Newer options with low VOCs.
Long lifespan.

The negatives of conformal coatings include:

Offers less robust protection against heavy-duty threats.
Contains VOCs within the solvents, though these are becoming less abundant.

Contact Us Today to Protect Your PCBA

If you’re still unsure about which option is best for your PCBA, our expert team of HZO engineers can help. We realize that your needs are just as unique as our coatings, so we will work closely with you to provide custom coating solutions.

To learn more, contact us or call us today at 1-877-757-4496.

Epoxy Conformal Coating Evaluation Guide

May 21, 2020 / by Mallory McGuinness-Hickey posted in Conformal Coatings, Coating Properties

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Conformal coatings are polymeric materials applied to substrates. These films protect electronics from environmental hazards, like corrosion, humidity, chemicals, and liquids. Popular conformal coating materials include silicone, acrylic, Parylene, and urethane. Epoxy is a top coating for applications that need high chemical and abrasion resistance.

What is Epoxy Conformal Coating?

Epoxy coatings are protective layers of polymeric material. They have excellent electrical, thermal, mechanical, and moisture barrier properties.

Epoxy coatings have the following attributes:

Very robust; difficult to remove the protective coating.
Excellent chemical and abrasion resistance
Very rigid conformal coating.
High dielectric strength

Epoxy Conformal Coating Applications

Epoxies are tough and highly abrasion-resistant. So, they are common in harsh environments, like automotive, marine, and military applications.

While exact figures for epoxy coatings specifically are not provided, the overall conformal coatings market is projected to see strong growth:

The global conformal coatings market is expected to reach $1.8 billion by 2028, growing at a CAGR of 5.3%. Some estimates project the market to reach $2.11 billion by 2034, with a CAGR of 6.7%.

Epoxy conformal coatings find use in various industries and applications:
• Consumer electronics
• Automotive electronics
• Aerospace and defense
• Industrial equipment
• Medical devices

They are particularly suitable for applications requiring rigid, durable coatings with good chemical and abrasion resistance.

Different types of epoxies have other benefits. For example, thermally conductive epoxy can protect boards with hot components. Meanwhile, flame-retardant epoxy protects against fire hazards. Clear epoxy allows for board visualization.

HZO provides Parylene conformal coatings applied with vacuum deposition, so our process is different. Watch this video to learn more.

What Does Epoxy Conformal Coating Protect Against?

Epoxy conformal coatings resist chemicals, alkalis, acids, moisture, solvents, and salt spray. They are known for excellent adhesion to various substrates without primers. They also retain this adhesion under many conditions. Additionally, they have good electrical properties. These remain stable despite humidity or high temperatures.

The Epoxy Conformal Coating Process

Applying epoxies with dip coating, brush, or spray application techniques is easy. Dip coating involves immersing a component in a tank of coating material. Brushing entails a manual application by an operator. The spraying method can be automated or manual, depending on production needs. Epoxy materials are a single or two-part compound. They require curing with UV or heat.

Learn About Conformal Coating vs. Potting

Epoxy Conformal Coating Pros and Cons

Advantages

Good abrasion resistance.
Good chemical resistance.
High tensile strength.
High Youngs Modulus.
Low coefficient of linear expansion.

Disadvantages

Higher water absorption than Parylene.
Rigid, can crack in vibration or thermal cycling.
Can shrink, causing stress on components/diodes.
Very difficult to rework.
Low impact resistance.
Low abrasion resistance compared to Parylene.

Why Choose Epoxy Conformal Coating to Protect Your Electronic Devices?

Epoxies have strong barrier properties; they are easy to process and cheap. That said, epoxy coating's toughness may complicate rework and removal. Film shrinkage may occur during polymerization, causing issues. The suggested thickness for epoxy coatings can reach 130 micrometers. This thickness may prove too bulky for applications that entail miniaturization.

Need help choosing a coating material for your next project? Contact us to discuss your application with a coating expert.

Solving Weather & Water Challenges For Smart Farms

May 12, 2020 / by Mallory McGuinness-Hickey posted in Parylene, Protection Capabilities, Thin Film Applications, Value of Coatings

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It’s a Small World, After All

The world’s population is projected to reach 8.5 billion by 2030, an unprecedented increase approaching fast. This looming surge will compound our current problem – more mouths to feed on a densely packed planet that isn’t growing any larger.

Even as available agricultural land shrinks and natural resources become more depleted, farmers must produce 70% more food by 2050.

Necessity is the mother of invention, especially when it comes to farming. After all, if the agricultural industry doesn’t adapt, we don’t eat. The task at hand for farmers is to produce more food with more precision while working with less.

IoT in Smart Farming: Connecting Dots

To adjust to these changes, the industry has introduced technology to agriculture, a practice known as smart farming. Intelligent devices collect and process information about emerging issues and environmental changes, enabling farmers to respond more quickly. Pulling this system together is the Internet of Things, connecting smart machines and integrated sensors to produce data-driven, data-enabled processes.

Information about the fertility of the soil, crop growth, weather conditions, and other variables can be used to track business status, equipment efficiency, and employee performance, offering valuable insights that can be used to optimize agricultural performance. As a result, work, waste, and risk are reduced, while cost management and capabilities are enhanced.

Hardware Security Implications in Smart Agriculture Pose Problems

While agricultural devices hold promise, no matter how smart the software may be, the success of the smart farming system is contingent upon how physically secure the hardware is. This is problematic for several reasons:

Without adequate protection, sensors can easily be damaged by wear and tear caused by constant exposure to drops, falls, heavy winds, or pounding rain.
Typical weather conditions, such as high temperatures, pollutants, condensation, and humidity, can cause immediate failure by a short circuit or a long, unpredictable shutdown due to corrosion.
To operate reliably, farm managers need to access information consistently. A single sensor failure could lead to a catastrophic period of downtime at worst. At best, failing devices create the need for continuous maintenance and replacement.

one phone underwater that is still working because of HZO protection and another that is dead because of water damage

Protecting Smart Farming Equipment Has Never Been This Important

The onus falls on the agricultural industry to achieve more precision and a higher level of performance as it struggles to meet the demands of our population. To farmers, physically robust hardware is more important than ever.

Weather stations located across fields offer insight into climate conditions, the optimal choice of crops, and potential actions that, when taken, could improve farming capacity. Meanwhile, sensors attached to cattle are helping farmers understand changes in health and activity levels for each animal and, collectively, the status of the entire herd.

Crop management devices produce data about crop health, precipitation, and temperature fluctuations, allowing farmers to mitigate risk and increase yield proactively. This kind of cognizance is gleaned from smart farming sensors, provided these devices can predictably perform in an unpredictable environment.

Overcoming Challenges to Device Security In Smart Farming with Parylene Thin-Film Coatings

Considered a “best-in-class” conformal coating in electronic, industrial, medical, and engineering industries, Parylene is a thin-film electronic protection solution that can address agricultural challenges. Applied with a vacuum deposition technique, Parylene coatings achieve dependable coverage free from imperfections like cracks or voids. The coating uniformly conforms to device topography, completely penetrating spaces as narrow as <0.01 mm.

Additionally, Parylene has good heat endurance. For example, Parylene C can offer durable environmental protection for ten years at 80°C. Providing mission-critical protection at thicknesses on the micron level, Parylene can endure temperatures and weather conditions that traditionally have been hurdles for smart farming devices.

If you have been tasked with designing or manufacturing smart farming devices that the industry can depend on, Parylene is an excellent way to achieve critical reliability. Please contact us today if you’d like to learn more about our Parylene solution.

Designing a Waterproof Product With IP Ratings

March 25, 2020 / by Mallory McGuinness-Hickey posted in Protection Capabilities

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The Big Picture: Manufacturers determine IP ratings, not an impartial group. Although these rating systems are useful for comparison purposes, they are not the panacea for rating electronic waterproof design.

If you are designing a waterproof product and using IP ratings as a measuring stick, you may want to reconsider. When people think about IP ratings, what they normally understand as “waterproof” are IPX5, IPX6, IPX7, and IPX8. However, this is a misrepresentation. So why do we use IP ratings to measure the amount of liquid protection a device has?

Do IP Standards Measure Liquid Protection, or Are They Just a Marketing Measure?

Consumers have been demanding waterproof electronics for a while now, and in the past, manufacturing marketing teams were happy to deliver what they didn’t necessarily have. Marketing teams, particularly for watches, showcased the word “waterproof” in their messaging. But these watches couldn’t stand up to liquid submersion.

In an attempt to clear the confusion, the International Organization for Standardization (ISO) replaced the word “waterproof” with “water-resistant This happened in 1990 when ISO issued the standard ISO 2281 for water-resistant products.

Nevertheless, a few years ago, commercials appeared with people using electronics in the shower, swimming with them in the pool, and dropping devices in the water – electronics, like smartphones, which, again, weren’t waterproof.

However, these commercials naturally led to the belief that the advertised products were, in fact, waterproof. However, customers described dropping so-called “waterproof” electronics for as little as 5 seconds, only to witness instant device destruction. The icing on the cake was that many manufacturers refused to mitigate liquid damage in their warranties.

As you might have imagined,lawsuits ensued.ISO tried to clarify again when they replaced the ISO 2281 standard with ISO 22810 to update the content in 2010.

Now, the term “water-resistant” describes products and the testing protocols created by the International Electrotechnical Commission (IEC) and ISO. Let’s look at some of those protocols now to understand how “waterproof” IP-rated devices are.

Learn more about NEMA vs IP ratings

What’s the Equivalent of IP Rated?

The first thing to know about IP testing protocols is that testing uses pure water only in laboratory conditions while the device is powered off.

Additionally, IP ratings only test for very specific environments.

IP Ratings only test for very specific environments

Relative humidity range – 20% to 75%
Air pressure range – 86 KPa to 106 KPa
Test samples should be completely new and clean.
Recommended temperature range – 15 C to 35 C

After testing, manufacturers inspect their devices’ enclosures for water ingress. Some water can even enter an enclosure and pass IP testing – under the condition that the exposure to water does not interfere with device operation or jeopardize user safety.

Do IP Standards Hold Up To Real Life?

Below are the requisites manufacturers must meet to deem a device “IP protected.”

The IPX6 standard test confirms that a device has suitable protection against heavy seas or powerful jets of water.

The IPX7 test attempts to determine whether electronic enclosures can provide enough protection from temporary immersion in water. A device will be immersed in water for a half-hour. The temperature of the product and the water cannot vary more than 5 C.

IPX8 tests for continuous immersion are completely subject to the manufacturer’s requisites. At the very least, they should be more severe than IPX7 conditions.

So, if you submerge a product from the box into 1 meter of fresh water inside a laboratory, your bases are covered. But what happens when you step outside the lab?

Learn about other standards, like Mil-i-46058c and UL94 ratings

The IP Rating System Won’t Help When Life Happens

There are a few glaring problems when it comes to calling an IP-rated device “waterproof” in real-life scenarios:

Device pressure is affected by how it enters the water for IPX7 and IPX8 tests. Fluctuations in pressure can affect the depth and time a product can be submerged in water.
Temperatures in bathrooms, bathtubs, steam rooms, or saunas will probably exceed the specific temperature range that manufacturers test for, making the physical seals meant to protect electronics less efficient at protecting the device.
The tests use fresh water. Freshwater starkly contrasts the water that devices typically encounter, like tap water, swimming pools, saltwater, bathtubs, or toilets.
Chemicals commonly used, like perfumes, oils, hair dyes, and solvents, can eat away at the mechanical parts and seals protecting a product, dragging the water-resistance level down.
The fact that a device can be placed under 1 meter of water is great, but in the real world, products will probably fall to the bottom, voiding the guarantee that water will not ingress.
The devices don’t have to be on during testing – if an electronic device is powered on underwater and is running programs, its internal temperature and pressure will increase, negatively affecting the depth of water the product can withstand.

Learn about hydrophilic coatings

How to Design a Truly Waterproof Electronic Device

If you want a waterproof (not “water-resistant”) device, you needParylene conformal coating. As we explained above, commonly used mechanical seals don’t cut it.

Parylene is a polymer that coats the circuit boards powering your devices from the inside out. It doesn’t add thickness or bulk to devices that other conformal coatings do, and our Parylene can nullify water damage and last up to 20 years. You can learn more about Parylene and our Parylene coating process here.

Learn more about our coatings

Not All Devices HAVE to be Completely Waterproof

Although the IP rating standards are nebulous, they’re still useful for comparison, and many manufacturers require IP testing for devices that aren’t completely mission-critical. That’s why plasma-based nano coatings are sought out by engineers looking for affordable, ultra-thin conformal coating – they can meet any IP rating reliably and with scale.

But we digress. So, is IP57 waterproof? The answer is no; it is just water-resistant. When you consider your mission-critical waterproof electronic design, remember that you aren’t building products for a lab; you’re building products for life on life’s terms.

Rakuten Kobo Chooses HZO | Waterproof Next Generation Ereader

August 17, 2016 / by Ryan Moore posted in Value of Coatings

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Consumer requests for waterproofing made possible with HZO Technology

Draper, UT – August 17, 2016 – HZO Inc., the total solutions leader in liquid and environment protection technology, announced its recent collaboration with Rakuten Kobo to protect its latest eReader, the Kobo Aura ONE. The HZO Protected™ Kobo Aura ONE is rated to IPX8, making it a versatile device that enables people to read in more places than ever.

HZO’s innovative thin-film coating solution will provide the Kobo Aura ONE with unmatched protection from damage caused by liquids and moisture without the need for bulky cases or mechanical seals, making Kobo’s new eReader sleeker, lighter and safe to use anywhere, including the beach or even in the bath.

Kobo conceptualized the Kobo Aura ONE with the input of its most avid readers. Of all their requests, water protection made the short list of the most desired features. With the customer in mind, Kobo answered the call for liquid protection, turning to HZO to make their customers’ desires a reality.

HZO collaborates extensively with product designers, engineers, and OEMs to integrate its protective technology into manufacturing. “An HZO Protected device lasts longer and performs better due to the internal application of HZO’s innovative protection layer,” said Max Sorenson, Chief Technology Officer at HZO. “Our transparent coating is microns thin, adds virtually no additional weight, and offers unmatched environmental protection.” This unique technology, combined with HZO’s collaborative engineering, made possible the IPX8 capabilities of the Aura ONE.

HZO enables OEMs and manufacturers by combining collaborative engineering with its patented manufacturing processes and its unique Parylene-based coating to protect electronic devices and components of all sizes and levels of complexity. OEMs can offer superior environmental, liquid, and submersion protection without compromising their devices’ design or overall performance.

The HZO Protected Kobo Aura ONE will be available globally in September; for more details: https://www.kobo.com

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About HZO:

HZO is a technology solutions and licensing company that provides electronics manufacturers and device makers in a range of industries, including consumer, medical, military, and industrial, with thin-film protection against damage caused by liquid submersion, corrosive environments, humidity, sweat, dust, and debris. With a scalable end-to-end solution that supports mass volume production and a technical team dedicated to innovation and customer success, HZO’s patent-protected solution enables product design freedom, delivers product differentiation, and goes beyond the boundaries defined by electronics testing standards like IPX8.

Don't Be Left in the Dark: Brief History of Light Emission Devices

April 28, 2015 / by Ryan Moore posted in Protection Capabilities, Thin Film Applications

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One of the best things about working for a company like HZO is the opportunity to be exposed to an extremely wide variety of technologies (apart from our own). Our seasoned technicians test and validate new products daily, from minuscule medical sensors to large electronic display boards. The technology driving these amazing devices is astounding. We could go on and on about the cool and fascinating technology that passes through an HZO production floor, but today we wanted to focus on one; the “Light Emitting Diode” or LED.

Behind most innovative technologies is an interesting story. Years and even centuries of trying, testing, and arduous development go into every bit of technology we now take for granted. The same is true of the “LED.” LED bulbs and displays have been in the mainstream for almost a decade now and are continuing to saturate the lighting world, but instead of focusing on the future applications for the technology, let’s review its history:

1907 – An Englishman named Henry Joseph Round discovers that inorganic materials (specifically, raw silicon carbide) can light up when an electric current is applied.
1921 – The Russian physicist Oleg Losev again observes the “Round effect” of light emission. In the preceding years, from 1924 to 1930, he published 16 papers outlining the LED and its applications.
1935 – French Physicist Georges Destriau discovers light emission in zinc sulfide. Today Destriau is credited as the inventor of electroluminescence.
1951 – The development of a transistor marks a scientific step forward in semiconductor physics.
1962 – American Dr. Nick Holonyak Jr. develops the first visible red LED. This marked the beginning of the industrially-produced LED.
1968 – The Monsanto Company produces visible red LED’s on a massive scale and becomes the first to produce affordable LEDs.
1971 – Due to the development of new semiconductor materials, LEDs are produced in new colors: green, orange, and yellow. The LED’s performance and effectiveness continue to improve.
1993 – Shuji Nakamura develops the first brilliant blue LED, which would be critical in developing the white LED. Nakamura (along with Isamu Akasaki and Hiroshi Amano) would win the 2014 Noble Prize in Physics for this discovery.
1995 – The first LED with white light from luminescence conversion is presented and launched on the market two years later.
2006 – The first light-emitting diodes with 100 lumens per watt are produced.
2010 – LEDs of multiple colors are being mass-produced with luminous efficacy of 250+ lumens.

Only a century ago, people accustomed to lighting candles and cleaning kerosene lamps stood in awe at the reliable glow of the incandescent lamps developed by Thomas Edison and his contemporaries in the late 1880s and early 90s. Now all we have to do is turn on our oversized TVs, glance at an electronic billboard driving down the freeway, or check the electronic scoreboard at a ball game to see what light has become. LEDs are everywhere, and we see them incorporated more into outdoor signage and advertisements. HZO is excited about this. These LED boards are exposed to everything Mother Nature can throw at them, and unless they are protected from the elements, the vital electronics will inevitably fail. HZO’s thin film barrier is highly reliable and able to extend the life of electronics thanks to our ability to meet the unique requirements of our customers. HZO goes well beyond water protection: It exceeds industry standards for salt, humidity, and temperature testing. As well as protecting against dust and debris, HZO coatings are transparent. So when protecting massive yet intricate LED boards, don’t settle for anything but the best.

HZO Investor Profile: Delta Electronics Capital

April 14, 2015 / by Ryan Moore posted in About HZO

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As HZO prepares for its first Board of Directors meeting of 2015, we are reminded of our amazing roster of investors. For a timely topic, today we highlight another of our Series B investment groups, Delta Electronics Capital, and one of our Board Advisors, AJ Dye.

Delta Electronics Capital is the investment arm of Delta Electronics, a Taiwan-based global leader in power and thermal management solutions. Delta Electronics Capital focuses on growth equity investments and strives to achieve the best balance between return and risk.

HZO is an excellent strategic fit for Delta Electronics and its mission to provide innovative, clean, and energy-efficient solutions for a better tomorrow. HZO’s chemistry is 100% organic. Our value proposition is to protect electronics from damage caused by everything from sweat and humidity to full and extended water and other liquids submersion. With HZO applied, electronics last significantly longer than devices with no protection and devices protected with inferior methods, including mechanical seals, acrylics, and urethanes. Devices incorporating HZO technology can potentially reduce tons and mounds of electronic waste.

HZO Board Observer, AJ Dye, works in the Denver office of Delta Electronics Capital, identifying and managing minority investments and acquisitions across North America in late-stage and middle-market energy, technology, and healthcare companies. In addition to HZO, AJ also holds advisory positions at SynCardia Systems, Inc., the exclusive provider of the Total Artificial Heart, and Wells Fargo’s Cleantech Innovation Incubator (IN2), which is co-administered by the Energy Department’s National Renewable Energy Laboratory (NREL).

We appreciate and look forward to AJ’s continued advice and ideas as HZO rapidly accelerates its growth trajectory.

HZO Investor Profile: Harris & Harris Group

February 12, 2015 / by Ryan Moore posted in About HZO

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Today, we highlight one of the earliest private equity investors in HZO, Harris & Harris, a publicly traded company listed on NASDAQ under the ticker symbol TINY. H&H follows a distinctive investment approach, described as BIOLOGY+, the intersection of biology and interdisciplinary innovation from other technical fields, including materials science, chemistry, physics, engineering, and electronics.

The H&H team spends significant time tracking and discussing promising new technologies. In HZO’s case, H&H foresaw the emergence of wearable technology and realized that for wearables to go mainstream, they needed to be safe when exposed to sweat and water and their resulting corrosion.

HZO is a good company in the H&H portfolio, including investments in other electronics-related companies, including semiconductors, telecommunications and data communications, and metrology and test measurement.

HZO Investor Profile: Prudence Holdings

December 29, 2014 / by Ryan Moore posted in About HZO

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As 2014 comes to a close, we want to introduce another of our investors, Prudence Holdings, a founding investor in HZO. You may not have heard of Prudence, as this New York-based private equity firm keeps a low profile while quietly building a roster of transformative and disruptive businesses. Prudence’s strategy is simple: proactively search for ways to solve big problems, then partner with experienced management teams to make them a reality from disrupting real estate with Urban Compass, traditional financial services with Blockchain, talent access with Thuzio, micropayments with ChangeCoin, smart household devices with InSensi, and of course, disrupting a world where liquids no longer destroy electronic devices by investing in HZO.

“We love what we do at Prudence,” commented Gavin Myers, Head of Direct Investments and HZO Board Member. “We believe that every one of our investments can transform an industry. The business case for HZO makes sense: billions of devices are sold annually, and virtually none are offered with liquid protection — and the only proven technology besides HZO is mechanical seals. But, seals have a lot of drawbacks: they are costly to implement, deteriorate and loosen with time, and do not scale down as devices become thinner and thinner. HZO solves all of these drawbacks.”

This holiday season, we tip our hat to the team at Prudence for playing a pivotal role in advising HZO and helping us shape our management team as we continue our mission to transform how electronics are protected from water, other liquids, dust, and corrosion.

HZO Investor Profile: Iron Gate Capital

September 25, 2014 / by Ryan Moore posted in About HZO

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What do an e-commerce company that serves emerging apparel brands (Branded Online), a post-bill audit and recovery service for large hospitals (AcuStream), an artificial heart company (Syncardia Systems), and a fast-casual restaurant chain (Smashburger) have in common? Each of these companies and HZO is a member of Iron Gate Capital’s exclusive portfolio and the lead investor in HZO’s Series II growth funding.

HZO is fortunate to have access to the savvy partners of Iron Gate, a private equity firm comprised of seasoned operating executives who invest their own capital in compelling opportunities. Iron Gate’s strategy is to target companies with proven products that meet real market needs, making no investments in either seed or early-stage venture deals. This investment validates that HZO has cleared major start-up hurdles and is now squarely operating in an accelerating growth stage of development.

In addition to tapping the experience and knowledge of the Iron Gate partners, HZO also has gained access to the firm’s investors and their networks to assist HZO in managing its dramatic growth. Iron Gate’s impressive group of private investors includes current and retired CEOs and Presidents from highly successful companies across a wide range of industries. HZO is already tapping this collective experience to ensure we flawlessly execute our customer agreements and continue to be the leading liquid protection solution across industrial applications, life science devices, and consumer electronics.

Stay tuned to the HZO blog to learn more about other investors who support the HZO mission.

HZO Success Story: NavELite

September 8, 2014 / by Ryan Moore posted in Thin Film Applications

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In 2013, Andy Wilson of NavELite faced a tough situation. As a former special forces soldier in the United States Army, Price was familiar with tight spots, but this was different. His new product, a ruggedized backlit wrist compass developed with a former military colleague, was designed to help improve ease of navigation for military personnel and outdoor adventurers alike. Well into production, though, his team realized that the ultrasonic welding engineered to protect the battery of the backlit compass was not preventing liquid ingress, and water was getting in and shorting the light.

“We weren’t sure what we would do,” noted Wilson. “The design was finalized, and the ship deadline was only a few months away, but our product did not meet our standards.”

What happened next could be considered serendipity, but shortly after the problem arose, Andy met one of HZO’s Business Leaders, Jaren Beckstrom, at a trade show in New Orleans.

The conversations in Louisiana acted as the catalyst for rapid action planning, and Jaren quickly mobilized the HZO technical team to start analysis on the device to discover and correct the failure points with a customized solution that would protect the battery. Once the analysis was complete and the application process implemented, the battery and compass were put through vigorous prolonged submersion tests to ensure ongoing functionality exceeding the rigorous demands of military spec requirements. The end result? A ruggedized and durable military compass that could survive the most hostile environments thrown at it.

“Not only did HZO solve the ingress problem, but NavELite decided that the value add to our product was powerful enough that it was worth highlighting HZO’s protection as the differentiating feature,’ Wilson said. ‘We ended up promoting the technology on our website and in our marketing materials, and even put HZO’s logo on the wristband to let customers know that a model of our compass had a superior level of protection.”

The results for the NavELite are a textbook example of how HZO Protection adds real value to products that need reliable protection from liquid submersion or any kind of corrosive environment.

Today, the wrist compass is a standard issue for service men and women worldwide and has attracted a variety of press attention, including a feature in Maxim Warrior, a reality show featuring Special Forces teams utilizing their skills to compete against one another.

The overwhelming demand for the HZO-protected NavELite compass has proven most exciting to us. When the company started selling the HZO Protected device, the waterproof wearable immediately took off, outselling the unprotected version 9:1 at a $50 premium. Proof that when HZO collaborates closely on a project with a partner, the solution provides a superior level of security for devices and has the power to drive demand and create an additional revenue stream for device makers, brands and manufacturers.

NavELite’s wrist compass featuring HZO Protection is available for purchase via the company’s website. Hop over to their site, look at this unique device, and see how an early adopter of HZO technology is benefiting from the power of superior liquid protection.

Hydrophilic vs Hydrophobic: What's The Difference?

November 14, 2012 / by Ryan Moore posted in Protection Capabilities

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Hydrophilic vs. Hydrophobic

Today’s technical terminology can be dizzying. On an average day here at HZO you hear people throw around words like nanotechnology and vapor deposition as casually as if they were talking about their neighbor’s cat.

Today, we will decipher a few of these words and talk more about what two of these terms, in particular, “hydrophilic” and “hydrophobic,” actually mean. Along the way, we will clarify how the two are similar and different and show which one applies to our HZO technology.

Curious? Keep on reading.

What Does Hydrophilic Mean?

Hydrophilic, defined by the Merriam-Webster Dictionary, is “of, relating to, or having a strong affinity for water.” This essentially means the ability to mix well, dissolve, or be attracted to water.

What does Hydrophobic Mean?

Hydrophobic, defined by the same dictionary, is defined as “resistant to or avoiding wetting.” Practically the opposite of hydrophilic!

What’s the difference between the two?

According to these straight definitions, we can see that these two terms are opposites. Something defined as hydrophilic is attracted to water, while something hydrophobic resists water. This means when hydrophobic items come in contact with liquids, water is encouraged to bead up and roll off the surface- almost pushing it away as a magnet pushes away metal objects.

A great example of something that is hydrophilic is self-cleaning glass. This special glass has been engineered and coated with a nano-sized, thin film. Instead of allowing water to form into droplets that bead up and roll off the glass, this cool nanotechnology helps tiny water molecules glide over the surface in a sheet, washing dirt or other debris away.

Learn More About our Protection Capabilities

For an example of a hydrophobic substance, look no further than HZO technology. Our thin-film nano-coating encourages water and other liquids to bead up and roll off whatever it is applied to, be it a cell phone, tablet, or tiny circuit board. Although this isn’t the main property of our different coatings (we would rather brag about the actual physical barrier it creates between liquids and the important electronic components being coated), the hydrophobic properties are an added bonus.

Which coating is better? Well, within the electronics industry, we want to keep water away from the important electrical components inside of devices. A coating that causes water to bead up and roll away will keep electronics alive and well long after contact with water – so the hydrophobic coating wins this time.

These days there are a lot of other nano-coating products out there that claim hydrophobicity yet don’t measure up. Not HZO.

Record-Breaking Sea Kayak Journey Around Ireland

June 4, 2012 / by Ryan Moore posted in Value of Coatings

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A few months back, we were contacted with news of an amazing man in Ireland who was going to attempt to break a world record- so we jumped at the chance to do our part in supporting him on his amazing journey.

Today, June 4^th, Adventurer Mike Jones of Cobh, Co Cork, Ireland, is setting off in his 18-foot long sea kayak in an attempt to paddle around the entire country of Ireland in a mere 35 days, hoping to not only break the current world record in the process but also raise €10,000, (which equals about $12,000,) Children’s Sunshine home and Laura Lynn house- both organizations that care for children with life-limiting conditions.

We were lucky enough to be able to send Mike one of our favorite toys for his adventure- an HZO Protected iPod Nano to keep him company while he paddled. He was excited to test it with a few barrel rolls in his kayak and test whatever the Atlantic Ocean and the North Sea could dish out.

Mike will have a tracking beacon on his kayak, so hopefully, we will receive updates on his progress as his journey progresses. We wish him luck and will keep you posted on his progress!

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