High-Resolution Conformal Coating Edge Printing with Laser Jetting
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Solution Overview
Problem
Conventional deposition techniques for conformal coatings on electronic components fail to adequately cover the edges, leading to incomplete coverage and increased component exposure to environmental hazards, necessitating thicker coatings that reduce component lifespan.
Innovation Solution
A novel deposition technique using laser-induced jetting or spraying to apply conformal coatings at high resolution directly on component edges, followed by UV curing, and subsequent application on remaining areas, ensuring precise coverage without the need for thicker coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional deposition techniques are used to apply conformal coating, then the coating material can be applied to the component surface, but the edges of the components are not covered well due to material drift away from edges to centers
Solution Approach 1:
The patent replaces conventional mechanical dispensing systems with a laser-induced jetting system. The laser energy field precisely controls material ejection from the substrate, enabling direct deposition onto component edges without mechanical contact. This substitution eliminates material drift and achieves complete edge coverage with high precision, resolving the contradiction between manufacturing precision and reliability.
Solution Approach 2:
The patent changes the physical state and delivery parameters of the conformal coating material by using laser-induced jetting. The laser parameters (energy, pulse duration, frequency) are controlled to eject material precisely onto edges. This parameter control enables thin, uniform coating at edges without the material drifting to centers, simultaneously improving edge coverage precision and ensuring reliable edge protection.
2Reliability
If a thick coating is used to ensure adequate edge coverage, then complete edge coverage is achieved, but the overall temperature the component is exposed to during operation increases and component life is shortened
Solution Approach 1:
The laser-induced jetting system enables precise material placement only where needed (on component edges) rather than applying thick uniform coatings across entire surfaces. This precision delivery method achieves reliable edge protection with minimal material thickness, reducing thermal exposure and preventing component life shortening while maintaining edge protection reliability.
Solution Approach 2:
The patent applies conformal coating material locally and selectively only to component edges where protection is needed, rather than applying thick coatings to entire components. The laser-induced jetting system deposits material precisely at edge locations with controlled thickness, achieving reliable edge protection without increasing overall component temperature exposure.
3Ease of manufacture
If a conventional dispenser is used for edge deposition, then the deposition process is simple, but the dispenser cannot penetrate close enough to each component's edges requiring thicker coating
Solution Approach 1:
The patent replaces the mechanical dispenser system with a laser-induced jetting system that uses energy fields to eject material. This substitution eliminates the physical size constraints of mechanical dispensers, allowing precise material delivery directly onto component edges from a relatively high distance (up to several mm), achieving both edge access precision and maintaining process simplicity.
4Manufacturing precision
If laser-induced jetting is used to transfer coating material from high distance, then high resolution edge coverage is achieved, but the system complexity increases
Solution Approach 1:
The laser-induced jetting system replaces complex mechanical positioning and contact-based dispensing mechanisms with a non-contact energy field system. The laser parameters control material ejection precision, achieving high-resolution edge coverage without the mechanical complexity of precision actuators and contact tips. The system achieves manufacturing precision through energy field control rather than mechanical means.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves high-resolution, complete edge coverage of conformal coatings, enhancing environmental protection and component longevity by minimizing exposure to environmental hazards while maintaining operational efficiency.
Implementation Method 1
laser-induced jetting or laser-induced spraying. Conventional dispensers may not be able to penetrate close enough to each component's edges
Implementation Method 2
laser-induced jetting or laser-induced spraying. Conventional dispensers may not be able to penetrate close enough to each component's edges
Implementation Method 3
with optional UV curing of the deposited coating material performed between the deposition steps
Data Source
Figure 1a~1b
Figure 1c
Figure 2
AI summary
Systems and methods that enable printing of conformal materials and other waterproof coating materials at high resolution. An initial printing of a material on edges of a component is performed at high resolution in a first printing step, and a subsequent printing of the material on remaining surfaces of the component is applied in a second printing step, with or without curing of the material printed on the edges between the two printing steps. The printing of the material may be performed by a laser-assisted deposition or using another dispensing system to achieve a high resolution printing of the material and a high printing speed.