In this era of technological innovation, all manufacturing units, OEMs, various small and medium-sized enterprises, large companies, and giant enterprises are fully penetrated by electronic devices and instruments. Even a one hour shutdown or electronic malfunction can cause significant economic losses. In addition, whether it is a simple or complex PCB layout or PCB assembly, printed circuit boards are critical components in any device or machine. When the PCB is placed in an external environment, the likelihood of failure increases due to pollution, humidity, or any form of thermal conditions. The maintenance, rework, depreciation of machinery/equipment, and reduced asset lifespan of PCBs indirectly affect work efficiency, rapid turnover, delayed order delivery, and increased defect rates, all of which may have financial impacts. Large scale production and more production issues. In order to enhance the advanced defense of PCBs against external environmental faults, there are some simple solutions that people can practice on their own. Read more to learn which solution is most suitable for your PCB distribution.

###Best Practices for Avoiding PCB Malfunctions

One of the common causes of circuit board failures in the external environment is mainly due to moisture/dampness on the circuit board. There are now different types of solutions to protect circuit boards from moisture. Whether it is outdoor sensor systems, high-energy motor controllers, high-power chargers, industrial load testers, ultrasonic technology, water treatment plants, robot cable components, aerospace, electronic equipment, marine technology, extreme outdoor PCB applications, or PCB components in telecommunications projects, when the PCB is exposed to humid environments, protective equipment, condensation, and other uncertainties caused by hazardous climate reactions may damage the circuit.

1. In addition to the chemical, industrial, medical, robotics, metal processing foundries, automotive industries, glass factories, microprocessor industries, agricultural sectors, airline operations, e-banking, and telecommunications industries, renewable energy, seawater treatment, and entire power plants all face these types of problems.

2. The simplest measure to prevent PCB failure in external environments due to moisture invasion is:

3. The PCB should be equipped with a tight enclosure and a strong sealing system. In some cases, a sturdy custom enclosure is required to protect the PCB from moisture. This includes situations where the housing needs to be opened regularly due to circuit wiring or other environmental conditions, which may involve drilling holes in the housing. Place the PCB in a box or enclosure with rounded sides to facilitate the quick drainage of condensate. Additionally, desiccants can be used to absorb moisture; these desiccants efficiently capture moisture inside the box. Apply a suitable conformal coating on the printed circuit board. When selecting coating materials, consider characteristics such as moisture resistance, chemical resistance, temperature range, and high protection against moisture, air gaps on the circuit board, rain, corrosive chemicals, saltwater, pesticides, rapid thermal changes, or other uncertain external climates. Consulting a professional PCB manufacturer is recommended to understand the flow rate and viscosity required for the conformal coating, especially for boards with many solder joints, sharp edges, and irregular topography. Use protective materials such as silicone or epoxy to embed the entire PCB, protecting it from external objects. PCB manufacturing technology now offers various options to achieve low thermal expansion and high thermal conductivity, addressing temperature control and solder joint strain issues. Effective PCB layout software can help integrate component specifications for embedded designs and verify and track appropriate components for specific materials or coatings.

4. PCB failure in outdoor environments due to thermal conditions:

5. In many cases, outdoor electrical equipment or equipment residing in control enclosures eventually fails or shuts down due to thermal conditions. Temperature extremes, either too high or too low, cause fluctuations that lead to PCB rework or repair. Overheating of electrical equipment or the extended service life of internal electronic components is a thermal issue of significant concern in external environments. Conversely, harsh hot climates may include solvents, oils, corrosive substances, sugary residues, saltwater, fibers, or dusty atmospheres. To avoid PCB failure during thermal issues, consider the following practices:

6. Regularly calculate and balance the internal heat of the circuit board. Choose the appropriate IP rating based on the harsh environment. Determine a suitable heat dissipation solution and installation process based on the installation location’s climate response. Use early detection methods for condensation to avoid excessively large or small PCB components. Regularly monitor and measure humidity (dry, humid, or very humid) and air temperature (maximum average temperature). Conduct thorough inspections of the installation area to understand the actual constraints faced by the electrical equipment. Regularly analyze and measure the air quality at the installation site.