HZO Inc. (Morrisville, North Carolina, USA) is a provider of conformal coatings solutions for electronics and many other products. These solutions can be applied in a variety of markets including consumer electronics, medical devices, aerospace, semiconductors, and more.
In a sponsored episode of the Materials Performance (MP) Interview Series, Sean Clancy, Ph.D.—Senior Director of Materials Science at HZO—shared industry insights gained from many years of performing root-cause failure analysis in these products and end markets.
The complete podcast is available for listening below and at www.materialsperformance.com/podcasts, with this summary collected with assistance from transcription service Otter.ai.
HZO’s Company Background and History
HZO was founded in 2011 with a vision to make electronic products fully submersible, and it has since grown into a global network of state-of-the-art coating facilities. Its headquarters are in Raleigh, North Carolina, USA, with a global presence in China, Vietnam, and Mexico.
The company specializes in the production of parylene conformal coatings for electronic products, which can offer protection in harsh environments.
Throughout the interview, Clancy discusses the importance of cleanliness prior to coating; the challenges of corrosion in electronics, and the role of enclosures in protection. He highlights the need for robust coatings that can withstand wide temperature fluctuations and corrosive environments.
Clancy also mentions the evolution of coatings technology, including hybrid coatings and a shift away from fluorochemicals. He emphasizes the importance of proper cleaning processes and the potential for growth in smart devices.
Sean Clancy’s Role and HZO’s Offerings
In introductory comments, Clancy explains how his role includes technical requests; the development and measurement of coatings; and process optimization.
HZO’s bread and butter, as he calls it, are parylene conformal coatings. These can coat everything within a coating chamber with a uniform thickness.
The downside of parylene is that it coats everything, including areas that should be masked off. Thus, it requires careful planning and masking.
Corrosion in Electronics: Basics and Client Needs
During the conversation, Clancy discusses the unique needs of HZO’s users and clients. These can include strict requirements for dielectric and chemical barriers.
He mentions a challenging application with the U.S. National Aeronautics and Space Administration (NASA), which required a precise coating thickness gradient across a sensor die.
Clancy then explains the general process of corrosion in electronics, involving dendritic growth and electrochemical migration. Corrosion requires ionic materials, moisture, and an electrical bias, which can be mitigated by cleaning, drying, and the proper use of coatings.
Importance of Cleanliness and Environmental Factors
Clancy emphasizes the importance of cleanliness before coating, as residues can affect the reliability of the product. He explains the challenges of no-clean processes, which require careful control to ensure that no ionic residues are left.
He then discusses the risks of different environments post-coating, such as wide temperature fluctuations in aerospace and high salt environments near the ocean.
He highlights the importance of well-matched coefficients of thermal expansion, which can prevent coatings from cracking or causing solder joint failure.
Risks in Manufacturing and Handling Operations
Clancy goes on to describe the corrosive residues that can occur during manufacturing and handling operations, such as acid etching baths and metal plating valves.
He explains the potential for residues from solder fluxes, finger oils, and skin contaminants. To prevent corrosion, another point of emphasis is proper rinsing and drying.
He notes that despite these challenges, electronics often work surprisingly well due to careful processes and attention to detail.
Role of Enclosures and Conformal Coatings
Next, Clancy discusses the role of enclosures—which he says can be a double-edged sword—in protecting electronics. With that context in mind, he explains the importance of designing enclosures to prevent water retention while allowing for ventilation or drainage.
Clancy emphasizes the need for what he calls “a belt and suspenders approach,” which combines coatings with enclosures for high reliability applications. He highlights the importance of conformal coatings as a backup to ensure the product remains functional, even if the enclosure fails.
Evolution of Conformal Coating Technologies
Clancy goes on to talk about the evolution of conformal coating technologies, including hybrid coatings and atomic layer deposition coatings. He mentions the environmental concerns leading to the phasing out of certain fluorochemicals and the need for alternatives.
Subsequently, he discusses the importance of not cutting corners in the process to ensure each product’s reliability. To ensure no ionic residues are present, he emphasizes the need for tight control and due diligence in no-clean manufacturing processes.
Future of Conformal Coatings and Market Demand
Finally, Sean predicts growth in the demand for conformal coatings due to the increasing use of smart devices and Industry 4.0, which is also known as the fourth industrial revolution (4IR). He notes the challenges of miniaturization and the need for precise masking technologies to protect critical areas.
In closing, Clancy discusses the importance of high reliability controllers and components in smart manufacturing equipment. He highlights the need for continuous innovation and adaptation to meet evolving market needs.
Source: HZO, www.hzo.com.