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Humidity Management of Outdoor Electronic Equipment Methods Pitfalls and Recommendations
Humidity Management of Outdoor Electronic Equipment Methods Pitfalls and Recommendations
Humidity Management of Outdoor Electronic Equipment Methods Pitfalls and Recommendations
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Abstract—The paper discusses the basics of the three ap- which results in resistance degradation leading to soft and/or
proaches to mitigation of humidity related failures namely hard equipment failures. Over last few years systematic, sci-
1) relative humidity control module (RHCM); ence based procedures were developed at Nortel Networks to
2) absolute humidity control (AHCM);
mitigate this type of reliability problems through the schemes
3) use of potting and coating, as well as conditions and limita-
tions of their applicability. called absolute humidity control module (AHCM) and relative
The RHCM approach (or Saturation Limit Control) uses heat humidity control module (RHCM) which rely, respectively, on
dissipation from electronics to maintain an appropriate tempera- minimizing the amount of water in the enclosure and on en-
ture difference between ambient and the critical surfaces to lower suring that critical surfaces are hotter than ambient dewpoint by
RH in their vicinity and at same time through the use of diffusion
plugs ensures a relatively fast humidity equilibration between the
a specified . At the same time, using conformal coating and
enclosure air and ambient to minimize condensation caused by potting for protection from moisture, an approach instinctively
cold fronts and radiation cooling. The AHCM approach relies on sought by designers has been reevaluated, including a specific
minimization of water ingress through selection of appropriate version of the last approach, grease and/or gel application for
materials and design and at same time uses desiccant to remove the
ensuring reliability of a field installable connectors and splices
water which made its way into the enclosure. The choice between
these schemes depends mostly on thermal considerations. The system working in the conditions of long term exposure to
more expensive and sensitive to errors AHCM scheme has to be 100% RH or, which is equivalent, immersed in liquid water [6].
used when the energy dissipation is either not high enough or it is In this paper the overview and scientific basis of the humidity
highly dependent on the traffic. The apparently obvious approach, management methods adopted is given which takes into ac-
use of potting and coatings is not recommended for printed circuit
boards due to its nondeterministic character related to the board count the experience gained while implementing the schemes
structure and manufacturing issues, an exception being the use of to Nortel equipment.
gels or greases for weatherproofing of outdoor connectors.
Index Terms—Absolute humidity management, coatings, con-
ductive filament, dewpoint management, diffusion, failure, gel, II. MOISTURE RELATED FAILURES
grease, humidity, metal migration, moisture, outdoor equipment,
outside plant, potting, printed circuit, relative humidity manage- Vast majority of failures attributed to moisture are related to
ment, reliability, saturation limit management, surface resistance, formation of electrically conductive aqueous paths on surfaces
water, weatherproofing. and interfaces. These can lead to both soft and hard failures. The
former, caused the substrate resistance degradation below the
I. INTRODUCTION tolerance of some attached components are frequently (mis)di-
agnosed as no-fault-founds (NFF) and, as such, are frequently
Fig. 1. Surface coverage with water as function of relative humidity for moderately adsorbing surfaces.
statistical thermodynamics lead to the expression (1) for the few as three monolayers are sometimes claimed to be sufficient
average number of monolayers on the surface and we have accepted the latter, more conservative limit as the
basis of our weatherproofing schemes. The dependence of the
(1) number of adsorbed monolayers of water on RH for moderately
and strongly adsorbing surfaces as given by (1a) and (1b) is
shown in Fig. 1.
where the relative humidity (RH) is expressed as a relative Hence, to ensure that the average number of adsorbed mono-
number in the 0–1 scale. layers of water does not exceed 3 it is necessary to maintain RH
Most surfaces encountered in practice (PCB materials, below the threshold value of 0.6 or 60%. However, one
epoxies, polyesters etc.) have moderately adsorbing surfaces has to bear in mind that the above reasoning based of the BET
for which the water adsorption energy is close to that of heat of isotherm applies only to clean surfaces. The presence of water
water condensation amounting to ca. 0.4 eV For (1) soluble impurities like salts or hygroscopic dust may cause for-
simplifies to mation of conductive aqueous layers at the deliquescence hu-
midity which may lie below RH of 60% [8]. Thus, maintaining
(1a) cleanliness of surfaces is also a very important aspect of weath-
erproofing.
For very high surface energy materials which strongly adsorb By definition, relative humidity at a given place is the ratio
water (ceramics, metals) , e.g., metals and some ce- of the absolute humidity at this place to the maximum possible
ramic materials (1) reduces to (saturated) absolute humidity at a the temperature of the place
(1b) (2)
which means that the most hydrophilic surfaces will adsorb only Thus, RH can be maintained below the threshold value either by
one monolayer of water more than the moderately adsorbing maximizing (“Saturation Limit Control”) or by min-
ones and that they will hold on to this monolayer even at very imizing of AH (“Dewpoint Control”). These two approaches
low humidity. This fact is well known from high vacuum studies have their respective advantages and disadvantages and both
of metal surfaces by XPS and Auger spectroscopy. On the other have been applied in Nortel products. The former is basis of
hand, very hydrophobic materials (e.g. PE, PTFE,) will resist the relative humidity control module (RHCM), the latter of the
formation of conductive water layers up to very high humidities. absolute humidity control module (AHCM). Yet another ap-
There is no general agreement as to the threshold thickness proach is to use some kind of protective coating or potting, an
required for ionic conductivity leading to failure. Values of eight approach where most misunderstanding exist. These three ap-
to ten monolayers are frequently assumed to be necessary but as proaches will be discussed in this paper (Fig. 2).
68 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 25, NO. 1, MARCH 2002
(3)
(5)
areas to a year in others [17]. According to (7), potting may have [3] D. J. Klinger, “Humidity acceleration factor for plastic packaged elec-
some effect in, e.g., Ontario ( for 1 cm polyurethane), tronic devices,” Qual. Rel. Eng. Int., vol. 7, pp. 365–370, 1991.
[4] D. Yan, S. L. Melink, G. W. Warren, and P. Wynblatt, “Water adsorp-
but not in Florida ( ). tion and surface conductivity measurements on a alumina substrates,”
It is good physical or chemical adhesion rather than barrier in Proceedings of the 36th Electronic Components Conference. New
properties can protect the board surface from moisture effects York: IEEE, 1986, pp. 95–99.
[5] N. L. Sbar and R. P. Kozakiewicz, “New acceleration factors for tem-
[6]. Unfortunately, with the current trend of dispensing with the perature, humidity, bias testing,” IEEE Trans. Electron. Devices, vol.
cleaning step after soldering, the reliability of potted boards may ED-26, pp. 56–71, Jan. 1979.
be even worse than that of untreated ones because water may stay [6] M. Tencer, “Conductive aqueous layer formation at the gel-substrate in-
terface,” IEEE Trans. Comp. Packag. Technol., vol. 23, pp. 693–699,
in a cavity between the board and the potting compound which in Dec. 2000.
the combination with ionic contamination may lead to resistance [7] M. Kitano et al., “Analysis of package cracking during reflow soldering
degradation and failure. Moreover, the water will not stop at the process,” in Proc. Int. Rel. Phys. Symp., 1988, pp. 90–95.
[8] ASHRAE Handbook, 1981 Fundamentals, American Society of
interface. It will continue inside the board and cause resistance Heating, Refrigerating, and Air-Conditioning Engineers, Inc.
degradation along glass fiber interfaces resulting in soft failures [9] S. Rolt, Nortel Networks, private communication to the author.
and copper electrochemical migration commonly known as con- [10] K. L. Dalgleish et al., “Wireless base station—Having cooling pas-
sages,” Tech. Rep. US5 548 643, 2001.
ductive anodic filament (CAF) formation [19], [24], [25]. Also, [11] T. Zapach, Nortel Networks, private communication to the author.
water will migrate into plastic components which contain cavity [12] J. S. Moss et al., “Enhanced humidity control for small modules,” Tech.
(e.g., MQUAD) where it can condense upon cooling. Moreover, Rep. US 6 128 193, 1996.
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There are however, systems where the approach can be suc- [14] A. Dyer, An Introduction to Zeolite Molecular Sieves. New York:
Wiley, 1988.
cessful. An example is automotive electronics where its success [15] UOP Molecular Sieves, product brochure (a reprint of, “Union Carbide
is due to constant heat/dry cycles; this way the moisture ingress molecular sieves),” Tech. Rep., 2001.
starts anew each time. Using greases and/or gels to protect out- [16] Climates of the World, U.S. Dept. Commerce, Jan. 1969, reprinted 1977.
[17] M. Tencer, “Moisture ingress into nonhermetic enclosures and packages:
door connectors as long as good adhesion and surface cleanli- A quasi steady state model for diffusion and attenuation of ambient hu-
ness is maintained [6] is another example as connectors have midity variations,” in Proc. 44th IEEE Electron. Comp. Conf., 1994, pp.
no internal structure which could fail due to water. Coating and 196–209.
[18] H. Yasuda, “Units of gas permeability constants,” J. Appl. Polym. Sci.,
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[20] S. Brunauer, P. H. Emmett, and E. Teller, “Adsorption of gases and va-
VI. CONCLUSIONS pors on solids,” J. Amer. Chem. Soc., vol. 60, pp. 309–319, 1938.
[21] C. G. Shirley, “Reliability of electronic packaging,” in Technical Sem-
Both hard and soft moisture related failures, the major relia- inar given at the 43rd Electronic Components and Technology Confer-
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[22] R. M. Barrer, Zeolites and Clay Minerals as Sorbents and Molecular
critical surfaces. The method of choice for humidity manage- Sieves. New York: Academic, 1978.
ment depends on functionality and design, especially thermal [23] ZEOCHEMO® molecular sieves type 4A, product brochure.
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in epoxy glass printed wiring boards,” in Proc. Int. Reliab. Phys. Symp.,
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dewpoint equilibration and prevention of water droplets intake. printed circuit materials,” in Proc. Printed Circuit World Conv. II, 1981,
pp. 80–93.
Absolute humidity (dewpoint) control gives the designer more
thermal headroom but it is more involved from the manufac-
turing point and less tolerant of error. Coating/potting is gen-
erally not recommended except for special applications, e.g.,
using gels for weatherproofing of outdoor connectors.
Michal Tencer received the M.Sc. degree in
organic chemistry from the Warsaw University of
ACKNOWLEDGMENT Technology, Warsaw, Poland, in 1970 and the Ph.D.
degree in molecular spectroscopy and stereochem-
The authors wish to thank T. Zapach, S. Rolt, and the other istry from the Polish Academy of Sciences in 1975.
members of the Nortel Interdisciplinary Team, for helping to From 1975 to 1981, he was with the Institute
develop this topic and introducing the resulting solutions into of Nuclear Research, Swierk, Poland. From 1981
to 1988, he held several academic positions in
design practice. physical organic chemistry, polymer chemistry and
photophysics, and materials for microelectronics at
REFERENCES the Swiss Federal Institute of Technology (ETH),
Zurich, University of Toronto, and Lehigh University. From 1988 to 1991, he
[1] W. Adamson, “Adsorption of gases and vapors on solids,” in Physical was Chief Chemist/Technical Director of the bio-materials company Acrylium-
Chemistry of Surfaces, 3rd ed. New York: Wiley, 1976, ch. 13, pp. Microbex, Inc., Unionville, ON, Canada. Since 1991, he has been with Nortel
585–595. Networks (formerly Bell-Northern Research), Ottawa, ON, where he has
[2] C. E. Hoge, “Corrosion criteria for electronic packaging, Part I—A worked in the area of materials, reliability, and electronic packaging. Currently,
framework for corrosion of integrated circuits,” IEEE Trans. Comp., he is Senior Member of Scientific Staff and oversees several projects related to
Hybrids, Manufact. Technol., vol. 13, pp. 1090–1097, Dec. 1990. optoelectronics.
72 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 25, NO. 1, MARCH 2002