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A Complete Guide to PCB Encapsulation

The process of PCB encapsulation has to do with the encapsulation or the

filling of electronic assemblies using a compound to offer some protection

from vibration and shock, contaminants like chemicals, moisture, and dust,

and corrosion. The electronic process of plotting also ensures the

protection of the components from any security threats like reverse

engineering or tampering.

In contrast to conformal coating, PCB encapsulation is more robust and

thicker, which helps in protecting the electronic assemblies from different

tin whiskers and harsh environments.

Table of Contents

What Does PCB Encapsulation Mean?

Another reliable method for offering protection to the PCBs from any

external damage is referred to as PCB encapsulation. You can also call

it PCB potting. From the name, encapsulation strives to surround your

PCB rather than just adding coat to it. The casing or pot will be built over

the printed circuit board and then the fluid will be poured in the casing,

thereby sealing the PCB up.

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Because they are two major component systems, the process of PCB

plotting deals with the mixing of resin and the hardener. Doing this will

create a form of chemical reaction, which creates the cross-linked polymer.

In order to boost the performance, resin feature mineral fillers, which

have greater viscosity. In addition, majority of resins are made to be

VOC-free and cure only at room temperature. This is why, PCB

coating sprays are not necessary.

Though it is possible to apply a casing of 0.5 mm, usually, they are much

thicker than this. With an increase in thickness also comes a weight

increase. This leads to higher expenses for each coating. Also, the

components will get better protection as a result of the increase in

thickness.

Pros

 Useful for high-volume applications

 Its dark color provides design security

 Provides greater protection against chock damage and water

Cons

 A significant increase in weight

 More process steps

 Costlier than the conformal coating

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PCB Encapsulation vs Conformal Coating

expoxy potting & Encapsulation

Choosing between conformal coating and circuit board encapsulation isn’t

about which method is best, rather it has to do with which of them suits

your needs. Concerning this, you’ll consider:

 The layout and the design of the PCB

 Its individual components

 The Use environment’s expected conditions

If you’ll be exposing your device to very extreme conditions,

choosing PCBA encapsulation will be a smart choice. This is because it

provides additional protection benefits. These environments

include power plants, mines, and manufacturing factories.

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Moreover, if flexibility is the major goal, i.e. when dealing with consumer

electronics, the better choice will be PCB coating. Electronic encapsulation

has to do with offering protection to the electronic assembly using a

compound as a form of defense from vibration and corrosion shock.

How to Perform PCB Encapsulation

PCB encapsulation or pcb plotting deals with sealing of the PCB in a thick

resin layer that offers great protection from harmful chemicals and

physical shock. This process enhances the PCB’s electrical performance.

To perform the PCB encapsulation,. You have to place your PCB assembly

inside an open pot and then add some liquid compound in it till the entire

PCBA becomes completely covered. This liquid has some hardener in it

that helps to speed up the curing, and whenever this liquid solidifies, it

plays a great protective role.

Normally, this resin utilized here is dark in color. This makes it very difficult

for anyone to see that board under it. The materials commonly used for

the plotting compounds include silicone, polyurethane, and pcb

encapsulation epoxy.

Different materials come with their own benefits and pitfalls, which should

be put into consideration. The applications determine your selection of

the best material. For instance, pcb encapsulation epoxy and silicone work

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best for circumstances surrounding high temperatures. Moreover,

urethane will offer a much better performance to chemicals. Therefo4e3,

the most important point when choosing the materials is that you need to

have a very good thought about the type of protection you desire.

When Should PCB Encapsulation be Used?

As already mentioned, PCB encapsulation provides great protection

performance. Therefore if you want your application or device to be able

to stand against abrasion, strong physical shocks, high temperature,

chemicals, abrasion, as well as moisture, PCB encapsulation should be the

next move. This is because it also includes the vibration damping option.

Also, PCB encapsulation can help in protecting engineering privacy. This is

possible due to its colored resin. This makes it difficult for the other

people around to see the underneath board region and then make some

profit from it.

However, this is a two-edged sword because this invisibility can bring in

some obstacles when there is need for a rework or repair. Also, potting is

important for all high volume work because it can be handled quickly on

any assembly line. Finally, PCB potting provides a great aegis against all

electrical arcs. Therefore, if you have high-voltage electrical devices, we

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advice that you make use of circuit board encapsulation rather than

conformal coating.

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What are the Benefits of PCB Encapsulation?

 Encapsulation offers full protection against water damage and

shock

 It provides a well-secure seal that prevents contaminants from

entering

 It protects against chemicals and corrosion

 A very reliable way of reducing RFI/EMI interference in different

devices

 Electronic components that are encapsulated provides a strong

foundation for any wire bonding through the reduction of stress on

the solder joints, which might have cause failure or breakage. This

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elimination of the exposed copper edges offers a reduced surface

area for the oxidation. It also offers better adhesion between the

solder pads and wires as well as better thermal performance.

 Encapsulation helps to protect against tin whiskers which are

harmful, by creating a form of environmental barrier.

 It also prevents the components from getting destroyed or

damaged because of external forces like mechanical vibration

 It ensures the best functionality of the device over time. Also, it

improves the insulation found between the electrical devices to

help in reducing the loss of current

 The reverse-engineer also finds encapsulated PCBs more difficult

compared to those with conformal coating that are applied to some

regions

 Also, it protects the components from experiencing thermal

expansion problems. Furthermore, it retains iconic purity as well as

properties relating to moisture resistance

 Generally, PCB encapsulation is faster and less expensive than the

other methods of protection. This is because it needs few

application steps and doesn’t need reassembling.

 VOC-free options are available

 Using the potting and encapsulation material is easy, even when

using high-volume applications

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What are the Applications of Encapsulation?

Encapsulation is applicable in different areas. These include photonics

encapsulation as well as its use in cables.

PCB Encapsulation

Encapsulants are useful for protecting electronic components like PCBs

that may experience damage as a result of moisture, mechanical vibration,

as well as other environmental factors.

Offers Protection to Electronic and Electrical Components

Encapsulation provides protection for the electronic and electrical

components from dust, dirt, water, as well as other contaminants.

Photonics Encapsulation

The encapsulated components are useful in applications including

photonic integrated circuit, manufacturing of LEDs, solar panels, and fiber

optics. Enclosures for optical instruments benefits from the utilization of

electronic encapsulants. Also, they offer protection to the optical elements

from any corrosion as well as prevent humidity and particles of dust from

having any interference with the performance.

Also, LCDs require some defense against any light interference as a result

of ultraviolet radiation. This is why they have to be encased in the

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encapsulant material. This helps in blocking UV rays coupled with

maintaining a clear and a viewable surface area.

Cables

At times, the encapsulants are utilized on different electrical cables like

twisted or coaxial pairs. They could get damaged easily due to oxidation

and several environmental factors. Even, it protects the inner wires from

exposure to moisture, chemicals, sunlight, or contaminants, as they could

affect the performance.

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What are the Required Materials for Encapsulation?

Materials involved in the process of circuit board encapsulation include

adhesives, potting compounds, and resins. The resins usually coat the

electronic devices during the electronic assembly. This helps in protecting

them from environmental contaminants or water. You may need

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adhesives during the attachment of the encapsulating material that is

found around the devices for protection.

This potting compound serves as an extra layer of protection for the

electrical components. It also ensures heat dissipation through the

conduction of excess thermal energy away. This prevents the extreme rise

of temperatures beyond the normal range that can cause component

failure.

Conclusion

One technology you must have if you wish to prolong your PCB’s lifetime

as well as reduce repair cost is PCB encapsulation. However, there is a

need for deep consideration when choosing the best technology for

your PCB projects as conformal coating and potting are two complex

processes. They are also full of variables, which may have an effect on the

final cost. However, if you have some doubts, then there is a need to

consult professionals in the field to help you out. They will have to

consider all the aspect of the project, budget, application, turnaround time,

etc. to be able to make the best choice for you.

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