High Performance Solutions for EV Charging Stations

A case study on how light-curable conformal coatings and encapsulants helped improve EV smart charging station infrastructure PCB applications.


Find an Easy-to-Use Conformal Coating With Superior Testing Performance

A developer and manufacturer of smart infrastructure (products and software) solutions for EV charging station networks was looking to improve the assembly of printed circuit boards and electronic modules and harnesses. Along with a conformal coating, that didn’t quite meet the testing requirements they needed, the company was using slow-curing two-part epoxies and silicones in their assembly process. They also required a damming material to protect critical keep-out areas on PC electronic modules and a product to pot and seal wire harnesses.


Light-Curable Conformal Coatings & Encapsulants That Offer a Greener Alternative to Solvent-Based Materials

The customer, seeking guidance on UV equipment and the light-curing process, was introduced to Dymax through its affiliate Electronic Coating Technologies. During equipment trials, the ECT team suggested switching to Dymax 9483 light/moisture-cure conformal coating to replace a competitive product, for its ease of use and superior testing performance.

The company was also interested in light-cure solutions for their module and harness applications for the many benefits the technology offers, including one-part materials, fast cure, increased throughput, less rework, and less waste.

9-20351-F flexible coating/encapsulant was suggested for damming around critical keep-out areas since it provides a good moisture barrier to electrical devices on PCBs. For potting and sealing of the wire harnesses, Multi-Cure® 9037-F encapsulant was chosen for its thixotropic, high-viscosity composition.


A Faster, "Greener" Assembly Process and Increased Efficiency & Throughput

Dymax 9483 conformal coating cures tack free with UV/Visible light first, and then with ambient moisture in 2-3 days, excelling in PCB applications where shadow areas are present. This re-workable coating is well suited for high-value boards and exhibits outstanding temperature, chemical, and corrosion resistance, as well as excellent thermal shock and high-temperature flexibility. It can be applied from 2 mils (0.002”) to 7 mils (0.007”) thick on rigid PCBs and flexible circuits, has no flash off, and fluoresces blue for quality inspection.

9-20351-F high-viscosity coating/encapsulant is engineered for application thicknesses between 2 mils (0.002”) to 20 mils (0.020”) making it ideal for potting and sealing inside wire harnesses. Its excellent moisture barrier properties and secondary heat-cure capability provide a solution for shadow areas on densely populated PCBs. Blue fluorescing makes the material easy to see, speeding the
up post-cure inspection process.

Multi-Cure® 9037-F encapsulant features excellent moisture and thermal resistance and is a good choice for use as a corrosion guard for wire-bond connections. Formulated with blue fluorescing technology, the material is highly visible on encapsulated PCB modules when exposed to low-intensity black light and is suited for simple visual or automated inspection systems. It also has a secondary heat cure for shadow areas. 9-20351-F and 9037-F both pass -40 to 150°C thermal shock and 85°C/95% R.H. testing.

Since all products are one-component, have no solvents added, and are environmentally friendly, there are no special requirements for disposal making for an overall “greener” process. By using Dymax light-curable materials, the company realized faster throughput due to rapid light cure, no pot life for less waste, no mixing, and cure on demand for less rework. The manufacturer was able to increase efficiency and save costs by reducing the overall processing time and scrap rate.

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