Three-Layer Coating for Electrical Components UV Removal

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Solution Overview

Problem

Conventional protective coatings for aircraft electrical components, such as Parylene, face issues with excessive creepage distance requirements at high voltage and altitude, poor ozone resistance, and hazardous solvent-based removal processes, necessitating an improved solution for enhanced protection and ease of maintenance.

Innovation Solution

A three-layer protective coating system comprising a UV breakable adhesive first layer, a Parylene-based second layer, and a silicone-based transparent third layer, with the option of a fourth adhesion promoter, where the third layer can transmit UV light to facilitate removal of the first layer, and is cured at 170°F for added durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If Parylene coating is used to protect electrical components, then protection from moisture and chemicals is improved, but creepage distance requirements increase at high voltage and altitude

Engineering Contradiction:

Improveprotection from moisture and chemicalsVSAvoidcreepage distance

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent applies a three-layer composite coating system where the first layer is a UV-curable adhesive, the second layer is Parylene, and the third layer is a silicone-based UV-curable coating. This composite structure combines the moisture and chemical resistance of Parylene with the tracking resistance and UV curability of silicone-based materials, resolving the contradiction between protection quality and creepage distance requirements at high voltage.

Inventive Principle:

Principle #40Composite materials

2Reliability

If Parylene coating is used to protect electrical components, then protection from elements is improved, but ozone resistance deteriorates

Engineering Contradiction:

Improveprotection from elementsVSAvoidozone resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The three-layer composite coating combines Parylene's element protection with silicone-based materials' superior ozone resistance in the third layer, creating a system that maintains protection from elements while significantly improving ozone resistance compared to pure Parylene coatings.

Inventive Principle:

Principle #40Composite materials

3Reliability

If Parylene coating is used to protect electrical components, then protection performance is improved, but removal process becomes hazardous requiring toxic solvents

Engineering Contradiction:

Improveprotection performanceVSAvoidhazardous removal process

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical removal process (using toxic solvents) with a photochemical process. The third silicone-based layer and first adhesive layer can be cured with UV light, enabling removal through UV activation rather than mechanical or chemical means, thereby eliminating the need for toxic and flammable solvents.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If conventional single-layer coating is used, then manufacturing process is simple, but protection against multiple hazards is insufficient

Engineering Contradiction:

Improvecoating process simplicityVSAvoidprotection against multiple hazards

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent implements a three-layer composite coating system where each layer provides specific protective functions: the first layer provides adhesion and UV curability, the second layer provides moisture and chemical resistance, and the third layer provides ozone resistance and UV curability. This composite structure achieves comprehensive protection against multiple hazards while maintaining a relatively simple manufacturing process through sequential coating and curing steps.

Inventive Principle:

Principle #40Composite materials

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

The coating system provides superior protection against moisture, ozone, and temperature, while allowing for safe and non-abrasive removal, maintaining component integrity and reducing maintenance hazards.

Implementation Method 1

The first protective layer can be removed while maintaining the second protective layer and maintaining the third protective layer by shining a UV ray at at least 350 nm frequency to degrade the first protective layer

Methodology Applied

Scientific EffectUV photodegradation: Photodissociation

Implementation Method 2

The method can further include plasma etching the second protective layer, wherein the plasma etching take place before coating with the third protective layer

Methodology Applied

Scientific EffectPlasma etching: Plasma

Data Source

PatentUS11589464B2Protective coating for electrical components and method of making the protective coating

Publication Date: 2023.02.21 HAMILTON SUNDSTRAND CORP

AI summary

A electronic component including a first protective layer covering the substrate and the conductive tract, a second protective layer covering at least a portion of the first protective layer, wherein the second protective layer includes Parylene, and a third protective layer covering at least a portion of the second protective layer.