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The liquid coatings can be applied by a variety of methods, including:
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Hand painting the coating with a brush Dipping the board into the coating Hand spraying with an aerosol can or handheld spray gun Automatically spraying the board with coating as it passes by on a conveyor Selectively applying coating to certain areas of the board with a robotic nozzle Vapor depositing para-xylylene onto the board with specialized equipment
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Hand Paint Hand painting allows coating to be applied wherever desired with no setup time and low equipment cost. It is still the preferred method for touching up thin spots in a bulk applied
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coating and for coating replaced components. It can be used to reach areas where spray or automatic nozzles cannot reach, and works well for smaller, one-of-a-kind items. Hand painting is the most variable of all methods. 41.4.2 Dip Dip coating works best for coatings that have a long pot life at room temperature, such as solvent evaporation cured coatings and one part materials. Since the unused coating remains in the dip tank, a long (or infinite) pot life keeps the waste down to a minimum. The viscosity of the material in the bath should be checked daily, using a flow cup viscosimeter or other method, and solvent added to keep the viscosity of the material within the acceptable range. For a given dip speed, a lower viscosity will produce a thinner coating. The dip machine (see Fig. 41.2) will have bars or hangars on which to hang the board to be coated. Insertion speed should be slow enough to prevent the formation of bubbles as the coating flows around and under surface mounted parts, etc.Withdrawal speed should range between 1 to 6 in./min and will dictate the finished coating thickness; a slower withdrawal will produce a thinner coating.
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FIGURE 41.2 Dip coating machine.
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Dip coating cannot be used multiple times to build up thicker layers of acrylic coating, since solvent in the bath will loosen or dissolve previously applied layers of acrylic. Any areas that are not to be coated must be completely masked before dipping. Assemblies can be partially dipped to leave the top edge of the board uncoated if the board is designed so that all components that need coating are below the level of the bath. 41.4.3 Hand Spray Hand spraying is used for all types of liquid coatings. The boards to be coated are sprayed several times; the angle is changed 90 each time so that complete coverage is achieved. Tall components may shadow or block the spray from lower profile components behind them, so care must be taken to ensure all areas of the board are fully coated. A witness strip is often sprayed at the same time for use in measuring the coating thickness. As with the dip method, viscosity control is a key factor to reducing bubbles, cobwebs, and improper coating thickness. Two part materials are mixed immediately prior to filling the spray gun container, or are mixed in line if a continuously fed mixing gun is used. Single-part materials (particularly acrylics) are also available in aerosol cans, eliminating mixing altogether.
CONFORMAL COATING
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.)
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