Tamper Resistant Coating Deposition Control via Temperature Feedback

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing thermal-spray systems for applying tamper-resistant coatings (TRCs) suffer from inconsistent deposition rates, affecting porosity, pore volume, and coating height, which are critical for mass-sensitive and height-sensitive applications, due to uncontrolled temperature variations during the process.

Innovation Solution

A system comprising a spray mechanism, a rotatable spray-target, temperature sensors, and a control system that monitors and adjusts the coating application based on real-time temperature measurements to maintain consistent TRC deposition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal spray process is used to apply TRC, then coating protection is achieved, but deposition rate becomes inconsistent

Engineering Contradiction:

Improvecoating protectionVSAvoiddeposition rate consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The system incorporates temperature sensors that continuously monitor the substrate temperature during the thermal spray process and feed this information back to the control system. The control system adjusts spray parameters in real-time based on this feedback to maintain consistent deposition rate and coating quality.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes process parameters (such as spray gun position, spray rate, and substrate temperature) during the coating process to optimize deposition consistency. Temperature control is used as a key parameter to regulate the thermal spray conditions and ensure uniform coating properties.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If thermal spray process is used to apply TRC, then coating protection is achieved, but porosity and pore volume become unpredictable

Engineering Contradiction:

Improvecoating protectionVSAvoidporosity control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Temperature sensors provide real-time feedback on substrate temperature during spraying, allowing the control system to adjust parameters to achieve consistent coating density and predictable porosity characteristics.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

By controlling and adjusting substrate temperature and spray parameters dynamically, the system achieves consistent coating microstructure with predictable porosity and pore volume, essential for mass-sensitive applications.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If thermal spray process is used to apply TRC, then coating protection is achieved, but coating height becomes unpredictable

Engineering Contradiction:

Improvecoating protectionVSAvoidcoating height control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The control system uses temperature feedback to regulate the thermal spray process, ensuring consistent coating buildup rate and predictable final coating height, which is critical for height-sensitive electronic components.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Dynamic adjustment of spray parameters and substrate temperature control enables precise regulation of coating deposition rate, achieving consistent and predictable coating height across the substrate surface.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If manual insertion and removal of circuits is required, then individual processing is achieved, but processing time increases

Engineering Contradiction:

Improveindividual processing capabilityVSAvoidprocessing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The system employs self-clamping fixtures that automatically secure circuits onto the spray target without manual intervention. The fixtures are designed to automatically release circuits after processing, enabling continuous operation and eliminating manual insertion and removal steps.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Circuits are pre-positioned on the spray target using automated loading mechanisms before the thermal spray process begins. This preliminary positioning eliminates the need for manual insertion during processing and enables streamlined production flow.

Inventive Principle:

Principle #10Preliminary action

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

This approach ensures consistent TRC deposition rates, improving the reliability and accuracy of the coating process by controlling temperature variations, thus enhancing the quality of the final product.

Implementation Method 1

Application of TRCs by heating a material to a molten state and spraying the molten material where desired is generally referred to herein as a 'thermal-spray process,' a 'thermal spray' or 'thermal spraying.'

Methodology Applied

Scientific EffectThermal spray:

Implementation Method 2

Methodology Applied

Scientific EffectTemperature sensing:

Data Source

PatentUS8210120B2Systems and methods for building tamper resistant coatings

Publication Date: 2012.07.03 MERCURY SISTEMS INC

AI summary

A system for building a TRC includes a spray mechanism for spraying a coating material, a target system including a rotatable spray-target that retains an object with a surface to be covered by the TRC, a temperature sensor, and a control system for controlling application of the coating material based on a temperature that is determined during the spraying. The temperature sensor may comprise a non-contact infrared sensor that may measure a temperature related to the object. The measured temperature may be controlled by varying the speed of the rotatable spray-target.