September, 2016
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tech.com
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Dual Applicators Improve High-Volume Non-Atomized Coating Continued from page 59
Furthermore, tall components can obstruct the dis- pense fan, requiring additional passes for complete coverage.
Needle Dispensing Needle applicators handle a wider range of
viscosities than film coaters and can be used for complementary applications. Needle dispensing uses fluid reservoir pressure to push the material through a needle to form a narrow bead, by way of time-pressure technology. The needle’s uniform, narrow pattern shape
enables contouring patterns, such as circles or 90° angles. Using a continuous path program routine can smooth contour lines seamlessly into a clean perimeter dispense. In some cases, needle applicators are used to
dispense a dam or gel material to restrict material flow. Staking materials, RTVs and gels are often used to hold components or protect connector com- ponents from contamination by the regular coating material. While the time-pressure needle applicator is practical for a broad range of materi- als, it lacks precise volume control.
Jet Dispensing A jet applicator has fine volume
control and positional accuracy, which allows it to dispense discrete dots. These dots are spaced far enough apart to reduce the volume of material applied, yet close enough together to flow and provide coating coverage. Lines are made up of a series of dots that blend together and parallel lines can create area coats.
For high-volume
manufacturers, automated selective coating systems provide an in-line,
hands-off process that
reduces or eliminates prod- uct handling by the opera- tors, protects the coated products, and optimizes UPH and repeatability.
By controlling the volume of a single dot, the system controls the volume of material dispensed across lines and coating patterns. While a film coater or spray can cause material to flood or contaminate keep-out zones, a jet dispenser can dispense into tight locations or close to a component in very thin lines without going out of bounds.
Pairing Applicators Needle and jet applicators can
be paired with non-atomized film applicators to gain the full benefit of dual applicators for high-volume elec- tronics manufacturing. Dispense needles are available
in different gauges, lengths and shapes to best meet the requirements of a particular application. A variety of tip options allow both jet and nee- dle applicators to fully access the areas around tall components as well as to provide narrow dispense widths. The flexibility of the applicator allows for finely-tuned conformal coat dispensing. By pairing a film coater with a
jet or needle-type applicator, confor- mal coating programs can take advantage of the film coater’s speed and broad passes while the paired applicator provides finesse and better access around vertical components. A jet applicator has the most volume dispense control, and the jet’s preci-
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sion reduces masking and rework. When the process is run by using a film coater and pairing it with a jet’s detail work, cycle time may be improved over a spray applicator moving at 200 mm/s (7.87 in/s). A dual applicator setup allows an operator to
dispense the border around keep-out zones and proceed to the larger volume dispense applicator within the same program. Dual-valve pairing enables high-volume manufacturers to create con- formal coating programs that maximize control and selectivity, increase throughput, and reduce waste and rework. On an automated conformal coating system,
Conformal coating program showing
dual-applicator dispensing. The blue area is film-coated and the yellow areas are the detail work of the jet applicator.
applicators are situated on the machine and the system can toggle the appropriate applicator as the program calls for it. In addition, the applica- tors have various tilt and rotate options for versa- tility. Ultimately, a well-rounded automated coat-
Continued on next page
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