IPC-HDBK-830

ASSOCIATION CONNECTING
ELECTRONICS INDUSTRIES ®

Guidelines for Design,

Selection and Application
of Conformal Coatings

Developed by the Conformal Coating Handbook Task Group (5-33c) of

the Cleaning and Coating Committee (5-30) of IPC

Users of this standard are encouraged to participate in the

development of future revisions.

Contact:

IPC
2215 Sanders Road
Northbrook, Illinois
60062-6135
Tel 847 509.9700
Fax 847 509.9798
October 2002 IPC-HDBK-830

Table of Contents
1 SCOPE ...................................................................... 1 5.2.1 Plating Surfaces ................................................ 10
1.1 Introduction ......................................................... 1 5.2.2 Alternate Surface Finishes ............................... 10
1.2 Purpose ................................................................ 1 5.2.3 Spacing .............................................................. 10
1.3 Scope ................................................................... 1 5.2.4 Solder Mask ...................................................... 10
1.4 Terms and Definitions ........................................ 1 5.3 Component ........................................................ 10
5.3.1 Component Material Type ................................ 10
2 QUALIFICATION AND SPECIFICATION
REFERENCES OF CONFORMAL 5.3.2 Through-Hole Components .............................. 11
COATINGS ................................................................ 3
5.3.3 Leaded SMT Components ................................ 11
2.1 ASTM International Standards .......................... 3 5.3.4 Leadless SMT Components .............................. 11
2.2 Federal Aviation Regulations (FAR) .................. 4 5.4 Electrical ........................................................... 12
2.3 IPC Standards ..................................................... 4 5.4.1 High Voltage (HV)/High Current (HC) ........... 12
2.4 Joint Industry Standard ...................................... 4 5.4.2 RF and Microwave ........................................... 12
2.5 Military Standards .............................................. 4 5.4.3 High Speed Digital ........................................... 13
2.6 Underwriters Laboratories .................................. 5 5.4.4 Controlled Impedance ...................................... 13
2.7 International Standards ....................................... 5 5.4.5 EMI/ESD .......................................................... 13
2.71 British Standards (DSTAN, UK Defence 5.5 Coating Coverage ............................................. 14
Standardization) .................................................. 5
5.6 Masking ............................................................ 14
2.7.2 IEC Standards ..................................................... 5
5.7 Drawings & Design Guidelines ....................... 14
2.8 Original Equipment Manufacturing (OEM)
Specification ........................................................ 5 5.8 Reworkability/Repairability .............................. 14

3 ENVIRONMENTAL, HEALTH AND SAFETY 6 RAW MATERIALS CHARACTERISTICS ............... 15

CONSIDERATIONS ................................................... 5 6.1 Viscosity ............................................................ 15
3.1 Emissions ............................................................ 5 6.1.1 Spindle Measurements ...................................... 15
3.2 Disposal of Hazardous Waste ............................ 5 6.2 Viscosity vs. Rheology ..................................... 15
3.3 Governmental Regulations ................................. 5 6.2.2 Flow Cup Measurements .................................. 16

4 TYPES OF CONFORMAL COATINGS .................... 5

6.3 Effect of Temperature ....................................... 16
4-1 AR – Acrylic ...................................................... 7 6.4 Surface Properties ............................................. 16
4.2 ER – Epoxy ........................................................ 7 7 COMPATIBILITY ..................................................... 16
4.3 SR – Silicone ...................................................... 7 7.1 Compatibility with Process Materials .............. 16
4.4 UR – Polyurethane ............................................. 7 7.1.1 Solder Masks .................................................... 16
4.5 XY – Poly-para-xylelene (parylene) .................. 8 7.1.2 Flux Residues ................................................... 17
4.6 Two-Part Systems (Acrylic/Polyurethane 7.1.3 Cleaning Media ................................................ 17
and Other Combinations) ................................... 8 7.1.4 Plasticizer .......................................................... 17
4.6.1 UV and Solvent Cure ......................................... 8 7.1.5 Defoamer .......................................................... 17
4.7 Other Types of Conformal Coatings .................. 8 7.1.6 Mold Release Agent ......................................... 17
4.7.1 Fluorocarbon (FC) .............................................. 8 7.1.7 Marking ............................................................. 17
4.7.2 Perfluoroether ...................................................... 8 7.1.8 Temporary Masking .......................................... 17
5 DESIGN FOR COATING APPLICATION ................. 9 7.2 Inhibition ........................................................... 18
5.1 Design Philosophy .............................................. 9 7.2.1 Types of Inhibition ........................................... 18
5.1.1 Defining Reliability Requirements ..................... 9 7.2.2 Location of Inhibition ...................................... 18
5.1.2 Understanding the Product Life Cycle .............. 9 7.2.3 Causes of Inhibition ......................................... 18
5.1.3 Defining the Product Environment .................... 9 7.2.4 Compatibility Check List ................................. 19
5.2 PCBs\Printed Circuit Boards .............................. 9 7.3 Adhesion ........................................................... 19

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7.3.1 Components ...................................................... 19 8.9.6 Catalytic Cure ................................................... 33

7.3.2 Surface Finishes ................................................ 19 8.10 Cure Process Considerations ............................ 33
7.3.3 Cleanliness ........................................................ 20 8.10.1 Cure By-Products ............................................. 34
7.4 Interlayer Adhesion .......................................... 20 8.10.2 Exotherm ........................................................... 34
7.5 Methods of Assessing Compatibility ............... 20 8.10.3 Shrinkage .......................................................... 34
8.10.4 Premature Surface Cure/Solvent Entrapment .. 34
8 PROCESSING ......................................................... 21
8.10.5 Exceeding Cure Recommendations ................. 34
8.1 Cleanliness ........................................................ 21
8.10.6 Layering ............................................................ 34
8.1.1 Cleaning ............................................................ 21
8.11 Application Process Monitoring ...................... 34
8.1.2 Cleanliness Assessment Techniques ................. 21
8.12 Inspection Guidelines ....................................... 35
8.1.3 Processing Environment ................................... 22
8.12.1 Magnification .................................................... 35
8.2 Substrate Preparation ........................................ 22
8.12.2 UV/Light Source .............................................. 35
8.2.1 Priming .............................................................. 23
8.12.3 Workmanship .................................................... 35
8.2.2 Plasma Treatment ............................................. 24
8.13 Environmental, Health and Safety
8.2.3 Mechanical Etching .......................................... 24
Processing Considerations ................................ 35
8.3 Masking ............................................................ 25
8.13.1 Viscosity Adjustment ........................................ 36
8.3.1 Types of Masks ................................................. 25
8.13.2 Spraying ............................................................ 36
8.3.2 Manual vs. Automated Masking ...................... 25
8.13.3 Dipping and Brushing ...................................... 36
8.3.3 De-masking ....................................................... 26
8.13.4 Vacuum Deposition .......................................... 36
8.4 Recommended Coverage .................................. 26
8.13.5 Curing ............................................................... 36
8.4.1 Recommended Thickness ................................. 26
8.4.2 Uneven Coating Thickness ............................... 27 9 FILM PROPERTIES ................................................ 36

8.4.3 Edge and Point Coverage ................................. 27 9.1 Appearance/Color ............................................. 37

9.2 Dielectric Properties ......................................... 37
8.4.4 Application Method .......................................... 27
9.2.1 Dielectric Withstanding Voltage (DWV) ......... 37
8.5 Shadowing/Bridging ......................................... 27
9.2.2 Insulation Resistance ........................................ 37
8.5.1 Accessibility Consideration .............................. 27
9.2.3 Q-Resonance ..................................................... 37
8.5.2 Curing Consideration ........................................ 28
9.2.4 Dielectric Constant and Dissipation Factor ..... 37
8.5.3 Shadowing Techniques ..................................... 28
9.3 Thermal Properties ........................................... 37
8.5.4 Bridging Techniques ......................................... 28
9.3.1 Thermal Stability .............................................. 38
8.6 Viscosity Adjustment ........................................ 28
9.3.2 Thermal Shock .................................................. 38
8.6.1 Methods of Viscosity Adjustment .................... 28
9.3.3 Glass Transition Temperature (Tg) ................... 38
8.6.2 Objectives of Viscosity Adjustment ................. 28
9.3.4 Coefficient of Thermal Expansion (CTE) ........ 38
8.7 Application Methods ........................................ 28
9.3.5 Temperature Gradient ....................................... 38
8.7.1 Manual Spraying .............................................. 28 9.4 Flammability ..................................................... 38
8.7.2 Automated Spraying ......................................... 29 9.5 Flexibility .......................................................... 38
8.7.3 Dipping ............................................................. 30 9.6 Abrasion Resistance ......................................... 39
8.7.4 Brushing ............................................................ 31 9.7 Coating Creep ................................................... 39
8.7.5 Selective Coating .............................................. 31 9.8 Hydrolytic Stability .......................................... 39
8.7.6 Vacuum Deposition (XY) ................................. 32 9.9 Permeability ...................................................... 39
8.8 Multi-Layering .................................................. 33 9.10 Chemical Compatibility and
8.9 Cure Mechanisms ............................................. 33 Chemical Resistance ......................................... 40
8.9.1 Room Temperature Cure .................................. 33 9.10.1 Fuel Resistance ................................................. 40
8.9.2 Heat Cure .......................................................... 33 9.10.2 Biological Compatibility .................................. 40
8.9.3 Heat Accelerable ............................................... 33 9.11 Gas Resistance .................................................. 40
8.9.4 UV Cure ............................................................ 33 9.12 Corrosion Resistance ........................................ 40
8.9.5 Moisture Cure ................................................... 33 9.13 Fungus Resistance ............................................ 40

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9.14 UV Stability ...................................................... 40 12.1.6 Blistering ........................................................... 47

9.15 Radiation Resistance ........................................ 41 12.1.7 Mealing ............................................................. 47
9.16 Outgassing ........................................................ 41 12.1.8 Charring ............................................................ 47
12.1.9 Degradation ....................................................... 47
10 REWORK AND REPAIR ....................................... 41
12.1.10 Chemical Attack ............................................... 47
10.1 Removal Methods ............................................. 41
12.2 Accelerated Testing .......................................... 47
10.1.1 Chemical ........................................................... 41
12.2.1 Test Parameters ................................................. 48
10.1.2 Mechanical Abrasion ........................................ 42
12.2.2 Examples of Tests ............................................. 48
10.1.3 Media Blasting .................................................. 42
10.1.4 Dry Ice Abrasion .............................................. 42 13 BIBLIOGRAPHY ................................................... 48
10.1.5 Thermal Degradation ........................................ 42
APPENDIX A Conformal Coating Comparison
10.1.6 Laser .................................................................. 42 Guide ..................................................... 49
10.1.7 Plasma ............................................................... 42 APPENDIX B Flow Cup Viscosity Measurement ..... 52
10.1.8 Combination Rework Methods ........................ 43 APPENDIX C Troubleshooting Guide ........................ 53
10.2 Cleaning After Stripping .................................. 43 APPENDIX D Thermal Analysis .................................. 57
10.3 Recoating .......................................................... 43 APPENDIX E Relative Humidity ................................. 58
10.4 Environmental, Health and Safety Rework APPENDIX F Time of Wetness .................................. 59
and Repair Considerations ............................... 43 APPENDIX G Atmospheric Particulates ................... 60
11 END USE ENVIRONMENT ................................... 43 APPENDIX H Airborne Contaminants ....................... 62
APPENDIX I Simulated Acid Rain Test .................... 66
11.1 Outdoor Environment ....................................... 44
APPENDIX J Coating for Medical Applications ...... 68
11.1.1 Ultraviolet (UV) Radiation .............................. 44
APPENDIX K Example of Stringent Test for Any
11.1.2 Humidity ........................................................... 44 Breach in A Conformal Coating .......... 70
11.1.3 Pollutant Gases ................................................. 44
INDEX ......................................................................... 71
11.1.4 Ozone ................................................................ 44
11.1.5 Acid Rain .......................................................... 44 Figures
11.1.6 Marine and Coastal Environment .................... 44
Figure 4-1 Conformal Coating Family Trees ...................... 6
11.2 Automotive ....................................................... 45 Figure 5-1 Assembly Drawing with Masking
11.3 Avionics Environment ...................................... 45 Requirements ................................................. 15
11.3.1 Aircraft on the Ground ..................................... 45 Figure 8-1 Options of Cleaning Systems According
to Flux Type .................................................... 22
11.3.2 Equipment Outside The Pressure
Figure 8-2 Cure Windows of Primer Cure ....................... 23
Containment Compartment
During Operations ............................................ 45 Figure 8-3 Conditions that Influence the Extent
of Primer Cure ................................................ 24
11.3.3 Equipment Inside The Pressure
Figure 8-4 Influence of Temperature and Humidity ......... 24
Containment Compartment
During Operations ............................................ 45 Figure 8-5 Masking Tapes ................................................ 26
11.4 Space Environment ........................................... 45 Figure 8-6 Masking Boots ................................................ 26
Figure 8-7 Spray Booth with a Manual Spray Gun ......... 29
11.5 Medical Environment ....................................... 46
Figure 8-8 Nonatomized Curtain Coater .......................... 30
11.6 Geothermal Environment ................................. 46
Figure 8-9 Swirl Applicator ............................................... 30
11.7 Nuclear Biological Chemical Warfare
Environment ...................................................... 46 Figure 8-10 Improvements in spray technology now
permit pattern widths as tight as 3.175 mm
[125 mil] for work around sensitive keep-out
12 LONG TERM RELIABILITY AND TESTING ....... 46
areas ............................................................... 30
12.1 Failure Mechanism ........................................... 46 Figure 8-11 Conveyorized Applicator ................................. 31
12.1.1 Wear/Abrasion .................................................. 46 Figure 8-12 Stand-Alone Batch Applicator ......................... 31
12.1.2 Loss of Transparency/Discoloration ................ 46 Figure 8-13 Automated Applicator ..................................... 32
12.1.3 Cracking ............................................................ 46 Figure 8-14 Dipping Equipment with Smaller PCAs .......... 32
12.1.4 Loss of Adhesion .............................................. 47 Figure 8-15 Dipping Equipment with Large PCAs ............. 32
12.1.5 Bubbles ............................................................. 47 Figure 8-16 Vapor Deposition Polymerization Unit ............ 33

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Figure 8-17 Loss of Conformal Coating Adhesion ............. 35 Table E-1 Critical Relative Humidity (CRH) For Several
Figure 8-18 Voids in Conformal Coating ............................ 36 Inorganic Compounds ....................................... 58
Table F-1 Time of Wetness ............................................... 59
Tables Table G-1 Deposition Rates for Particles .......................... 61

Table 11-1 Temperature Classifications Table H-1 Ambient Air Pollution Levels ............................. 62
of Automotive Industry ...................................... 45 Table H-2 Dry Deposition Measurements .......................... 63
Table B-1 Conversion Chart for Flow Cup Viscosity Table H-3 Highest Levels of Wet Deposition ..................... 64
Measurements ................................................... 52 Table H-4 Concentration of Selected Gaseous Air
Table C-1 Troubleshooting Guide ...................................... 53 Constituents in US ............................................ 64
Table D-1 Molecular Interpretation .................................... 57 Table H-5 Indoor Pollution Levels in the Far East ............ 65
Table D-2 Measurement Methods ..................................... 57 Table I-1 Acid Rain Formula for Testing Purposes .......... 66

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October 2002 IPC-HDBK-830

Guidelines for Design, Selection and

Application of Conformal Coatings
1 SCOPE • To inhibit arcing, corona and St. Elmo’s Fire.
1.1 Introduction Conformal coatings are used in con- • To provide mechanical support for small parts that cannot
junction with printed circuit assemblies (PCAs). The be secured by mechanical means, to prevent damages due
designer and the users of conformal coatings for electron- to mechanical shock and vibration.
ics applications should be aware of the properties of vari-
1.4 Terms and Definitions
ous types of conformal coatings and their interactions with
PCAs to protect the PCAs in the end-use environment for Acetone – A volatile fragrant flammable liquid ketone
the design-life of the PCA (or beyond). This document has C3H6O used chiefly as a solvent and in organic synthesis.
been written to assist the designers and users of conformal
Adhesion promotion – The chemical process of preparing
coatings in understanding the characteristics of various
a surface to enhance its ability to be bonded to another sur-
coating types, as well as the factors that can modify those
face, i.e., a layer of conformal coating.
properties when the coatings are applied. Understanding
and accounting for these materials can ensure the reliabil- Adhesion failure – The rupture of an adhesive bond such
ity and function of electronics. that the separation appears to be at the adhesive-adherent
interface.
1.2 Purpose The purpose of this handbook is to assist
the individuals who either make choices regarding confor- Anisotropic – Having properties that vary depending on the
mal coating or who work in coating operations. This hand- direction of measurement.
book represents the compiled knowledge and experience of
Anthropogenic – Relating to or resulting from the influ-
the IPC Conformal Coating Handbook Task Group. It is
ence of human beings on nature.
not enough to understand the properties of the various con-
formal coatings, the user needs to understand what is to be ARUR – Abbreviation standing for acrylic resin and ure-
achieved by applying the conformal coating and how to thane resin combination chemistries.
verify that the desired results have been realized. Bridging – Fillet or meniscus formation of coating around
1.3 Scope Conformal coating, for the purpose of this the leads of a component caused by capillary action.
document, is defined as a thin, transparent, polymeric coat- Creep – Strain, deformation, or movement of coatings
ing that is applied to the surfaces of PCAs to provide pro- caused by time and/or temperature.
tection from the end-use environment. Typical coating
thickness ranges from 12.5 µm [0.49 mil] to 200 µm [7.9 Cross-linking – The formation of chemical bonds between
mil]. molecules in a thermosetting resin during a polymerization
reaction.
Processing characteristics and curing mechanisms are
dependent on the coating chemistries used. The desired CTE – (Coefficient of Thermal Expansion) Linear dimen-
performance characteristics of a conformal coating depend sional change with respect to an original dimension due to
on the application and should be considered when selecting a change in temperature.
coating materials and coating processes. Users are urged to Cure – A change in the physical properties of a polymer by
consult the suppliers for detailed technical data. a chemical reaction.
This guide enables a user to select a conformal coating Degradation – Decrease in quality or integrity. Loss of
based on industry experience and pertinent considerations. desired physical, chemical or electrical properties.
It is the responsibility of the user to determine the suit-
ability, via appropriate testing, of the selected coating and Delamination – A separation between a conformal coating
application method for a particular end use application. layer and the surface it is adhering to.

A conformal coating may have several functions depending De-masking – The process of removing or disengaging a
on the type of application. The most common are: maskant film, tape, boot or plug.
• To inhibit current leakage and short circuit due to humid- De-wetting – The propensity of the coating material to
ity and contamination from service environment. refuse to wet the surface evenly.
• To inhibit corrosion. Dielectric constant – The ratio of the capacitance of a con-
• To improve fatigue life of solder joints to leadless pack- figuration of electrodes with a specific material as the
ages. dielectric between them to the capacitance of the same