Meaning
Material properties that describe how the physical dimensions of a substance change with variations in temperature govern the mechanical stresses developed within multi-material assemblies. The thermal expansion coefficient of the potting compound must match that of the printed circuit board and the electronic components to prevent solder joint failures during thermal cycling. Large differences in this value can lead to mechanical stress that cracks components or delaminates the board.
Stress Generation
When materials with different expansion rates are bonded together and subjected to temperature changes, they expand at different rates. This differential expansion creates shear stresses at the interfaces between the materials.
Material Matching
Selecting a potting compound with a thermal expansion coefficient that is close to that of the FR4 substrate reduces these localized stresses. This matching is particularly critical for devices that will experience extreme temperature transitions, such as automotive or outdoor industrial sensors.
Reliability Testing
The long-term reliability of the assembly is evaluated by subjecting test units to rapid temperature transitions in a thermal shock chamber. This testing simulates the environmental stresses that the device will encounter over its operational lifetime. If the materials are mismatched, the repeated cycling will cause the potting compound to separate from the enclosure or the circuit board.
Such separation can create paths for moisture ingress, which can lead to electrical shorts and premature failure of the product.