The importance of Conformal Coating in industrial electronic products

In the era of modern industry, electronics play a central role in almost every sector. From control panels in factories to monitoring systems in production facilities, industrial electronics have become indispensable. However, these electronic components are often exposed to harsh environments such as dust, moisture, chemicals and mechanical shocks, which can compromise their performance and lifespan..

This is where conformal coating comes into play. Today, on the I&A Blog, we are going to talk about the importance of conformal coating in industrial electronic products, covering its benefits, common types, application process and how it represents a great gain in availability and operational safety for industrial plants.

What is Conformal Coating?

Before going into details, it is essential to understand what conformal coating is and what its main benefits are. The process involves the application of a specialized chemical compound during the production of electronic products to protect their circuit boards, connectors and vital components against the harmful effects of the environment. This coating precisely covers every part of the device, ensuring its integrity and functionality..

There are several types of conformal coating that can be applied to protect industrial electronic products from dangerous factors, the most commonly being:

Acrylic coating: These coatings are versatile, quick-drying, and create a thin protective layer. They are ideal for applications that require frequent maintenance, as they are relatively easy to remove and reapply..

Silicone coating: Offers high resistance to humidity, extreme temperatures and thermal shocks. They are the preferred choice for harsh industrial environments such as Oil & Gas units.

Urethane coating: Known for their durability and chemical resistance, these coatings are suitable for electronics exposed to corrosive products in chemical plants or laboratories.

Parylene coating: Alied by vapor deposition, they create an ultra-thin, uniform layer that penetrates small details. They are excellent in resistance to moisture and chemicals, although the application process is more complex.

The choice of conformal coating depends on the specific demands of the application and environment where the product will be applied. Each type offers its own advantages and limitations, ensuring the protection of electronic components and extending the useful life of industrial products.

Conformal Coating application process on electronic products

The conformal coating application process plays a crucial role in the protection of industrial electronic products. A successful application ensures that electronic components are adequately protected against the harsh elements of the industrial environment. The process generally follows a serie of four critical steps:

1. Surface Preparation: Before applying the coating, it is essential to prepare the surface of the electronic components. This involves removing any contamination such as oils, dust and residue to ensure proper coating adhesion.

2. Choice of Application Method: There are several application methods available, including dipping, spraying, brushing and dripping. The method depends on the type of coating chosen, the application specifications and the characteristics of the electronic components.

3. Application of Conformal Coating: The coating is applied uniformly to the electronic components. This ensures that all critical areas and details are properly protected.

4. Curing: After application, the coating must go through the curing process. Curing can be done through heat or a cold curing process, depending on the type of conformal coating used. This process allows the coating to dry and harden properly.

To ensure effective protection of industrial electronic components, coating must be applied carefully and precisely. Well-executed processes increase product reliability, extend their useful life and reduce the risk of failures caused by humidity, dust and chemicals in the environment. Therefore, choosing the correct application method and carrying out the necessary procedures are essential for the success of the protection offered by conformal coating.

Benefits of Conformal Coating on electronic products

Conformal coating offers a series of crucial benefits for electronic products used in industrial environments. Its main function is to act as an effective protective barrier against moisture, preventing corrosion of sensitive components. This functionality is vital in industry-specific applications, such as control systems on ships and offshore platforms, water treatment plants and other sanitation applications.

It is also capable of protecting the electronic circuits against the dust and foreign particles, preventing short circuits and system failures. This characteristic protects electronic products present in applications in different industry segments, such as agroindustry and mining. It protects against the penetration of micro-particles from grain processing, common in storage warehouses, or the ore extraction process.

Another significant benefit is resistance to aggressive chemicals, which are common in industrial environments. Conformal coating prevents damage to electronic circuits caused by corrosive chemicals. This property is extremely relevant in petrochemical plants, an environment with the presence of multiple chemical compounds and applications that demand high availability.

Furthermore, this coating provides resistance to mechanical shocks and vibrancy, especially important in industrial applications that involve constant movement and handling of equipment. This functionality is essential in automotive assembly lines and in metallurgical units.

The application of conformal coating can also help extend the useful life of electronic products, resulting in considerable savings on downtime for maintenance and equipment replacement. Overall, the benefits of conformal coating include greater reliability, reduced downtime and greater operational efficiency, making it essential for the protection and performance of industrial electronics.

Altus PLCs with Conformal Coating

A reference in the national industrial automation market, Altus values the quality, performance and reliability of the programmable controllers it develops and produces. One of the crucial steps Altus takes to ensure its products meet the highest standards is the application of conformal coating during the manufacturing process.

Many of the solutions where our PLCs are used are applications in harsh industrial environments, such as factories, plants and offshore systems. The application of conformal coating protects the electronic circuits of these controllers against moisture, dust, corrosive chemicals and vibrations, ensuring their reliable operation. Furthermore, the process applied in Altus PLCs extends its useful life, reducing maintenance and equipment replacement costs.

To meet the requirements of these applications, Conformal Coating is applied to the programmable controllers of Nexto Series, Nexto Xpress IoT-ready PLCs, and all units of Hadron Xtorm RTUs.

In order to meet the standards arising from different segments and countries, Altus has been constantly improving its coating applying process for more than three decades. In it, a film between 25 and 50 micrometers is applied, adapting to the shape of the electronic board and its components. By doing this, the electronic components and other metallized areas are covered and protected from corrosion and electrical micro shorts, which guarantees an increase in the product`s useful life.

The silicone used to coat the plates of Altus products are in compliance with the standards of IPC-CC-830 and the military MiL I-46058C, in addition to being recognized by UL746E and UL746C, significantly increasing its useful life and guaranteeing its protection against corrosive environments.

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After applying the product, the electronic board undergoes a controlled drying process, where it is exposed to an oven with a temperature set at 60°C for 3 minutes. The applied coating protects the printed circuit board and the component solder with a very high degree of efficiency, as described in the IEC standards on Conformal Coating.

The process applied by Altus follows the specifications of the IEC 61010-1 and IEC 61010-2-201 standards, referenced by the IEC 61131-2:2017 standard, which places level 2 protection against pollution as the standard. This means operating in an atmosphere with non-conductive foreign matter, which may eventually be conductive for a brief period due to expected condensation, thus being equivalent and in some cases exceeding the aforementioned standards!