Application and Benefits of
Vacuum Impregnation When
Sealing Electronic Components
Chris Russell
Vice President, Sales and Marketing
Magna-Tech Manufacturing, a Henkel company
Introductions
Chris Russell
Vice President, Sales & Marketing
crussell@magnatechmfg.com
• 11 years within the Vacuum Impregnation Industry
• Ball State University
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Objectives
• Identify the root cause of electronic component sealing
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failures
Review traditional sealing methods
• Potting compounds
• Silicone and other wire blocking materials
• Hard gaskets and o-rings
• Form-in place gaskets (FIPG) and Cure-in-place gaskets
(CIPG
Introduce vacuum impregnation as a sealing solution
Henkel Capabilities
April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Root cause of component sealing failures
• Tiny voids, holes and micro leak paths are inherent in
many molded electronic components and wires.
• In the harsh environments in which many of these
electronics operate, moisture and other corrosive agents
can ultimately lead to part failure.
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Root cause of component sealing failures
• These conditions can result in intrusion of
foreign materials such as fluids, gases
and other corrosive agents which can
ultimately lead to part or field failure.
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Root cause of component sealing failures
Part Failure Between
Metal Pin and Plastic Interface
• Most electronic components and
wires have a leak path that can be
witnessed by applying as little as 5psi
of air pressure to the part.
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Electronic/Electrical Devices
Application Examples with Potential Leak Paths
• Powertrain Electronics
• Engine & transmission control
• Modules
• Connectors
Wire Harnesses
Connectors
• Safety & Driver Assistance
• Electronic brake modules
• Airbag modules
• Chassis control modules
• Steering control modules
Sensors
Encapsulated Coils
• AEV Power Generation Systems
• Batteries, fuel cells
• Electric motors
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Connectors & Power Supplies
Pressure Monitoring Systems
Climate / Thermal Systems
Automotive Lighting
Wire Harnesses
April 26, 2016
Fuel Injectors
Thermistors
Circuit Boards
Solenoids
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Agenda
Identify the root cause of electronic
component sealing failures
Review traditional sealing methods
Introduce vacuum impregnation sealing
solution
Henkel Capabilities
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Traditional Sealing Solutions
Potting compounds
• Advantage
• Quick and common application
• Disadvantages
• Surface seal
• Changes dimensional attributes
Silicone blocked wire
• Advantage
• Silicone blocked wire can be produced in whole reels
• Disadvantages
• Some applications don’t allow silicone
• Silicone could leach from the wire
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Traditional Sealing Solutions
Hard Gaskets & O-Rings
• Advantage
• Quick, replaceable application
• Disadvantage
• Only provides an interface seal
Form-in-place gaskets (FIPG) and
Cure-in place gaskets (CIPG)
• Advantage
• Durable interface seal between 2 unique components
• Disadvantage
• Other areas of the component remain unsealed
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Agenda
Identify the root cause of electronic
component sealing failures
Review traditional sealing methods
Introduce vacuum impregnation
sealing solution
Henkel Capabilities
11
April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Vacuum Impregnation Overview
• For the past 60 years vacuum impregnation has been most commonly associated
with the sealing of porosity in castings such as engine blocks, transmission cases
and other various components that have pressure retention requirements.
• In the early 90’s it was realized that the vacuum impregnation technology could be
used to seal electronic components and wires that faced similar
pressure retention requirements.
• Vacuum Impregnation is a batch process for sealing electronic components that is
inexpensive, robust and volume friendly.
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Basic Principal of Vacuum Impregnation
Purpose
• To remove the air or gas from the void within the
part and fill it with resin to eliminate potential leak
paths
Types of Leak Paths
• Void that exists between two dissimilar materials of
a over molded connector or encapsulated coil
• Through the jacket, between the jacket and
conductor or the between the strands of the
conductor of a wire or wire harness
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Vacuum Impregnation Process
The most common vacuum impregnation method is DVP (Dry Vacuum Pressure.) This cycle
requires two tanks, one which holds the sealant and one in which the parts are processed.
Process Steps:
• Place parts in processing basket
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Vacuum Impregnation Process
Process Steps (continued):
• Load basket into the Vacuum Impregnation Vessel
• Draw vacuum in process tank to remove air from voids in the parts
• Transfer sealant from storage tank to process tank and submerge
parts while still under vacuum
• Release vacuum and pressurize process tank with compressed air
• Pressure helps to drive the sealant into the voids
• Release pressure and transfer sealant back to storage tank
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Vacuum Impregnation Process
Process Steps (continued):
• Remove basket of parts from Impregnation
Vessel
• Transfer basket to centrifuge to remove
excess resin
• Wash in water and mild detergent to
remove resin from exterior of the part
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Electronics Impregnation Overview
• The resin used in the vacuum impregnation
process is an advanced polymer compound
that resists common solvents such as oil,
glycol, caustics, acid solutions, and water.
• Once cured, the impregnated part
maintains its flexibility with no change to its
appearance or dimensions.
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Electronics Impregnation as the Solution
• The resin has an ultraviolet tracer
added to identify the resin under a
black light.
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Impregnated Electronic Connectors and Coils
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April 26, 2016
Over molded Connectors
Encapsulated Coils
Sensors (i.e., ABS Brake, EFS, Speed)
Solenoids
Fuel Vapor Management Systems
Fuel Tank Power Pass-Through
Thermistors
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Characteristics of the Resin Impregnated Electronic Connectors
and Coils
• Methacrylate Monomer Resin – A Thermoset Material
• Crosslinks into a solid, yet flexible material that allows the resin to “move” with the
contraction and expansion of the two dissimilar materials
• Fills all voids and leak paths to prevent moisture and contaminants from entering the
preexisting void
• Completely washes from the outside of components removing all excess resin from
the metal pins and connection points
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Impregnated Wires and Wire Harnesses
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Pre-Cut Bulk Wire
Cut and Stripped Wire
Multi-Conductor Wire
Terminated Wire
Wire with Over molded Grommets
and Components
• Complete Wire Harness
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Characteristics of the Resin Impregnated Wires and Wire
Harnesses
• Methacrylate Monomer Resin – A Thermoset Material
• Crosslinks into a solid, yet flexible material that allows the wire to maintain flexibility
• Fills all voids and leak paths to prevent moisture and contaminants from entering the
wire or cable
• Completely washes from the outside of the wire and associated components
• Resin impregnated wires and wire harnesses can be soldered, welded, and crimped
post processing
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Sealing Solutions Comparison
Key Advantage Technology - LOCTITE Impregnation
Top Coat
Potting
UV,
Epoxy
UV,
Epoxy
Adhesive is fully exposed to environment:
• Subject to degradation
Small sealing are between molded plastic and metal insert:
• Short sealing path
• Low strength against thermal stress
• Higher weight (compared to Flexseal)
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April 26, 2016
O-Ring
LOCTITE Flexseal
Loctite
Flexseal
O-Ring
Use of O-rings:
• O-ring cost
• Assembly cost
• Inventory
Not possible to use flat pins / lead
frame
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Drop-in Solution for leakage problems
Reliable long term solution
No design change required
Low cost solution
Offered as Service, no investment required
Flexseal developed for E/E applications
Unique in the market
No visible sealants
Cosmetically Clean
More bonding Surface
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
What is NOT Affected by Vacuum Impregnation
• Dimensional attributes
• Electrical properties
• Terminals, leads or pins
• There is no exterior visual evidence of the
sealing process
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
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Industries Utilizing Vacuum Impregnation Today
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April 26, 2016
Automotive
Rail
Off-Highway
Communications
Military
Marine (Underwater)
Recreational Vehicles
Vending
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Agenda
Identify the root cause of electronic
component sealing failures
Review traditional sealing methods
Introduce vacuum impregnation sealing
solution
Henkel Capabilities
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Strength Of Henkel-MagnaTech:
Expertise With Strong Focus On Service
Employee
• Expertise with broad range of impregnation products
• Strong service business focus and aggressive growth approach
• Highly motivated teams of impregnation experts
• Strong Service-Center presence in North America & Mexico in a market
Regions
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Customer &
Applications
Technologies
leading position
Center located in strategic key region in NA/LAN
• Existing attractive applications in the Automotive industry
• Full range on local customer approvals
• Long standing relation ship with 250 OEM’s and Automotive supplier
• Comprehensive experience at difference impregnation lines and processes.
• Full service approach: process centers, on-site + off-site and related ancillary
service
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Resins
LOCTITE
High-Performance Impregnation Products
LIS
Chemical
type
Cure method
Appearance
Viscosity
23°C mPa.s
Chemical
resistance
Temperature
resistance
Resin
recycling
Application
area
LOCTITE IS 5100
Methacrylate
Anaerobic
Clear,
fluorescent
5 – 30
Excellent
-54°C to
+177°C
No
Electronics
LOCTITE IS 5110
Methacrylate
Anaerobic
Clear,
fluorescent
36 – 66 at
25°C
Excellent
+205°C
No
Electronics
LOCTITE IS AT
Methacrylate
Anaerobic
Clear,
fluorescent
5 – 15
Excellent
+177°C
No
Electronics
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Types of Impregnation Equipment
• Smaller, medium to low volume
front load modular system that can
be automated or manual with the
option to add modules as demand
increases.
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Types of Impregnation Equipment
• Larger, high volume batch systems
that can be automated or manual
operation
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April 26, 2016
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Henkel Global LIS Footprint
Automotive Electronic / Electric Impregnation
LIS Electronic Center Presence:
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EU:
1x Center
NA/LAN:
3x Center
AP:
1x Center
Japan + South Korea
South-East Asia
IMEA
LAS
April 26, 2016
LIS Electronics
Application and Benefits of Vacuum Impregnation When Sealing Electronic Components
Thank you!
Chris Russell
Vice President, Sales & Marketing
crussell@magnatechmfg.com