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Automatic Spray For high-volume coating application, a semiautomatic spray machine is used to eliminate the dependency on the operator and allow in-line coating. The boards enter the machine on a paper-covered conveyer and are sprayed by a rotating or reciprocating spray head. The motion of the spray head(s) is designed to cover a given width of the belt completely from all angles. Shadowing is of greater concern with semiautomatic spray equipment, since special treatment cannot be given to any one area of the board. Full masking is required to keep the coating out of areas that should not be coated. Once the board is coated on one side, it is partially cured (or fully cured), turned over, and coated on the other side.

Selective Coating The selective coating process utilizes a robot similar to the automated pick-and-place machine to dispense coating only where it is needed. Four or five axis machines can be used to coat the sides of tall parts and around corners. The greatest benefit to selective coating is that it drastically reduces the amount of labor needed for masking and mask removal; areas that need to be free of coating simply have no coating applied there. Coating utilization is highest of all methods, since almost no coating is lost in continuous production. Spray patterns may be either atomized, spraying droplets onto the board and providing a thinner coating (see Fig. 41.3), or continuous, applying a stream or sheet of liquid to the board

FIGURE 41.3 Selective coating using an atomizing nozzle. (Courtesy of Asymtek.)

FIGURE 41.4 Selective coating using a continuous flow nozzle. (Courtesy of Chipco. Inc.)

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(Fig. 41.4), producing a well-defined boundary between the coated and uncoated areas and eliminating the need for masking. In the same way as the semiautomatic sprayer, the board is tack-cured and then turned over and coated on the other side.An automated board flipper may be used to accomplish this to automating the entire coating process. 41.4.6 Vapor Deposition Vapor deposition is only used with XY coatings, and requires specialized coating equipment. In the evaporator, a measured amount of dimer is placed in a crucible. The coating cycle is then started, and the chamber is pumped down to an almost complete vacuum (see Fig. 41.5).

4. Look for areas where the program might be getting stuck in a loop. 5. Pay special attention to the operation of various cogs and how they interact with

During the deposition process, the dimer powder is vaporized and recondenses onto the batch of CCAs, forming a uniform coating covering all corners and edges evenly. The vapor deposition process drives the vapor into any crevices and openings.Vapor deposition has the most stringent masking requirements, since leaks in the maskant will still admit vapor that will contaminate the surface behind, and air pockets inside masking boots or tape may dislodge the boot in the vacuum and create leaks as the air escapes.

The finishing steps require most of the labor involved in conformal coating process. Three finishing operations are:

Curing the coating Inspecting under UV light to verify complete coverage and touch-up Removing mask materials

Cure Each of the four liquid chemistries is available in a formulation offering different cure mechanisms, as shown in Table 411 41511 Solvent Evaporation Systems that are cured by solvent evaporation can be air dried, or slightly heated to drive the solvent out faster Care must be taken not to overheat the freshly coated assemblies; the coating will skin over and cause bubbles Long-term exposure to the unevaporated solvents trapped in the coating may also be deleterious to the materials in the parts and PWB Drying of solvent cure assemblies must be done under a ventilation hood or other properly ventilated area 41512 Room Temperature Vulcanization (RTV) Some silicone-based coatings use the room temperature vulcanization (RTV) cure process, which consumes moisture from the surrounding environment as part of the cure process.

Some means of humidity control is required; if cure is attempted in a dry oven, the material will not cure properly, if at all 41513 Heat Cure Oven-curable systems use an extended bake, ranging from 15 min to several hours or longer, for the material to cure fully Thermally activated systems require the increased temperature to start the curing process, whereas thermally accelerated systems will cure eventually at room temperature but are baked to speed up the process and improve material properties Generally, the hotter the oven, the quicker the cure, and the harder the finished material 41514 UV Cure For high-volume production, UV-curable materials are used Immediately after the coating machine is a booth with high-intensity ultraviolet lamps to illuminate the assembly.