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A Complete Guide to PCB Encapsulation
The process of PCB encapsulation has to do with the encapsulation or the
filling of electronic assemblies using a compound to offer some protection
from vibration and shock, contaminants like chemicals, moisture, and dust,
and corrosion. The electronic process of plotting also ensures the
protection of the components from any security threats like reverse
engineering or tampering.
In contrast to conformal coating, PCB encapsulation is more robust and
thicker, which helps in protecting the electronic assemblies from different
tin whiskers and harsh environments.
Table of Contents
What Does PCB Encapsulation Mean?
Another reliable method for offering protection to the PCBs from any
external damage is referred to as PCB encapsulation. You can also call
it PCB potting. From the name, encapsulation strives to surround your
PCB rather than just adding coat to it. The casing or pot will be built over
the printed circuit board and then the fluid will be poured in the casing,
thereby sealing the PCB up.
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Because they are two major component systems, the process of PCB
plotting deals with the mixing of resin and the hardener. Doing this will
create a form of chemical reaction, which creates the cross-linked polymer.
In order to boost the performance, resin feature mineral fillers, which
have greater viscosity. In addition, majority of resins are made to be
VOC-free and cure only at room temperature. This is why, PCB
coating sprays are not necessary.
Though it is possible to apply a casing of 0.5 mm, usually, they are much
thicker than this. With an increase in thickness also comes a weight
increase. This leads to higher expenses for each coating. Also, the
components will get better protection as a result of the increase in
thickness.
Pros
Useful for high-volume applications
Its dark color provides design security
Provides greater protection against chock damage and water
Cons
A significant increase in weight
More process steps
Costlier than the conformal coating
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PCB Encapsulation vs Conformal Coating
expoxy potting & Encapsulation
Choosing between conformal coating and circuit board encapsulation isn’t
about which method is best, rather it has to do with which of them suits
your needs. Concerning this, you’ll consider:
The layout and the design of the PCB
Its individual components
The Use environment’s expected conditions
If you’ll be exposing your device to very extreme conditions,
choosing PCBA encapsulation will be a smart choice. This is because it
provides additional protection benefits. These environments
include power plants, mines, and manufacturing factories.
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Moreover, if flexibility is the major goal, i.e. when dealing with consumer
electronics, the better choice will be PCB coating. Electronic encapsulation
has to do with offering protection to the electronic assembly using a
compound as a form of defense from vibration and corrosion shock.
How to Perform PCB Encapsulation
PCB encapsulation or pcb plotting deals with sealing of the PCB in a thick
resin layer that offers great protection from harmful chemicals and
physical shock. This process enhances the PCB’s electrical performance.
To perform the PCB encapsulation,. You have to place your PCB assembly
inside an open pot and then add some liquid compound in it till the entire
PCBA becomes completely covered. This liquid has some hardener in it
that helps to speed up the curing, and whenever this liquid solidifies, it
plays a great protective role.
Normally, this resin utilized here is dark in color. This makes it very difficult
for anyone to see that board under it. The materials commonly used for
the plotting compounds include silicone, polyurethane, and pcb
encapsulation epoxy.
Different materials come with their own benefits and pitfalls, which should
be put into consideration. The applications determine your selection of
the best material. For instance, pcb encapsulation epoxy and silicone work
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best for circumstances surrounding high temperatures. Moreover,
urethane will offer a much better performance to chemicals. Therefo4e3,
the most important point when choosing the materials is that you need to
have a very good thought about the type of protection you desire.
When Should PCB Encapsulation be Used?
As already mentioned, PCB encapsulation provides great protection
performance. Therefore if you want your application or device to be able
to stand against abrasion, strong physical shocks, high temperature,
chemicals, abrasion, as well as moisture, PCB encapsulation should be the
next move. This is because it also includes the vibration damping option.
Also, PCB encapsulation can help in protecting engineering privacy. This is
possible due to its colored resin. This makes it difficult for the other
people around to see the underneath board region and then make some
profit from it.
However, this is a two-edged sword because this invisibility can bring in
some obstacles when there is need for a rework or repair. Also, potting is
important for all high volume work because it can be handled quickly on
any assembly line. Finally, PCB potting provides a great aegis against all
electrical arcs. Therefore, if you have high-voltage electrical devices, we
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advice that you make use of circuit board encapsulation rather than
conformal coating.
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What are the Benefits of PCB Encapsulation?
Encapsulation offers full protection against water damage and
shock
It provides a well-secure seal that prevents contaminants from
entering
It protects against chemicals and corrosion
A very reliable way of reducing RFI/EMI interference in different
devices
Electronic components that are encapsulated provides a strong
foundation for any wire bonding through the reduction of stress on
the solder joints, which might have cause failure or breakage. This
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elimination of the exposed copper edges offers a reduced surface
area for the oxidation. It also offers better adhesion between the
solder pads and wires as well as better thermal performance.
Encapsulation helps to protect against tin whiskers which are
harmful, by creating a form of environmental barrier.
It also prevents the components from getting destroyed or
damaged because of external forces like mechanical vibration
It ensures the best functionality of the device over time. Also, it
improves the insulation found between the electrical devices to
help in reducing the loss of current
The reverse-engineer also finds encapsulated PCBs more difficult
compared to those with conformal coating that are applied to some
regions
Also, it protects the components from experiencing thermal
expansion problems. Furthermore, it retains iconic purity as well as
properties relating to moisture resistance
Generally, PCB encapsulation is faster and less expensive than the
other methods of protection. This is because it needs few
application steps and doesn’t need reassembling.
VOC-free options are available
Using the potting and encapsulation material is easy, even when
using high-volume applications
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What are the Applications of Encapsulation?
Encapsulation is applicable in different areas. These include photonics
encapsulation as well as its use in cables.
PCB Encapsulation
Encapsulants are useful for protecting electronic components like PCBs
that may experience damage as a result of moisture, mechanical vibration,
as well as other environmental factors.
Offers Protection to Electronic and Electrical Components
Encapsulation provides protection for the electronic and electrical
components from dust, dirt, water, as well as other contaminants.
Photonics Encapsulation
The encapsulated components are useful in applications including
photonic integrated circuit, manufacturing of LEDs, solar panels, and fiber
optics. Enclosures for optical instruments benefits from the utilization of
electronic encapsulants. Also, they offer protection to the optical elements
from any corrosion as well as prevent humidity and particles of dust from
having any interference with the performance.
Also, LCDs require some defense against any light interference as a result
of ultraviolet radiation. This is why they have to be encased in the
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encapsulant material. This helps in blocking UV rays coupled with
maintaining a clear and a viewable surface area.
Cables
At times, the encapsulants are utilized on different electrical cables like
twisted or coaxial pairs. They could get damaged easily due to oxidation
and several environmental factors. Even, it protects the inner wires from
exposure to moisture, chemicals, sunlight, or contaminants, as they could
affect the performance.
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What are the Required Materials for Encapsulation?
Materials involved in the process of circuit board encapsulation include
adhesives, potting compounds, and resins. The resins usually coat the
electronic devices during the electronic assembly. This helps in protecting
them from environmental contaminants or water. You may need
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adhesives during the attachment of the encapsulating material that is
found around the devices for protection.
This potting compound serves as an extra layer of protection for the
electrical components. It also ensures heat dissipation through the
conduction of excess thermal energy away. This prevents the extreme rise
of temperatures beyond the normal range that can cause component
failure.
Conclusion
One technology you must have if you wish to prolong your PCB’s lifetime
as well as reduce repair cost is PCB encapsulation. However, there is a
need for deep consideration when choosing the best technology for
your PCB projects as conformal coating and potting are two complex
processes. They are also full of variables, which may have an effect on the
final cost. However, if you have some doubts, then there is a need to
consult professionals in the field to help you out. They will have to
consider all the aspect of the project, budget, application, turnaround time,
etc. to be able to make the best choice for you.
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