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Comments on PCB as a wall of an underwater enclosure

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PCB as a wall of an underwater enclosure

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Can a circuit board be waterproof enough to form a wall of a waterproof enclosure?

Regular PCBs made of FR-4 with solder mask is what I have in mind. But I'm not barring less common PCB materials and processes, although I'd prefer something with moderate cost in moderate quantities.

10m depth in river and sea water.
Temperature range between +4°C and +40°C.
An ability to withstand freezing temperatures isn't required. But it's desirable, because that would let me field-test the device year round where I live.

Why would I want to expose a PCB to water? The malice aforethought is that the PCB has electrodes on the water side and a connector on the dry side. Here’s a rough and naïve sketch of what I have in mind.

front with electrodes rear with a connector

Solder mask overlaps the edges of the electrodes, and prevents water from getting under the electrodes.

Is ENIG plating enough to provide corrosion resistance for the exposed parts of the electrodes?

Vias are tented (or plugged, or via-in-pad, if necessary).

My findings so far:

I asked several PCB suppliers at a trade show about waterproofing PCBs, and one of them mentioned in passing that solder mask is waterproof. The common solder mask materials are epoxies (from what I read on the web), and epoxies can make good water resistant coatings. Two layers of solder mask, if coverage defects are a concern.

The wiki about FR-4 says that it has “near-zero water absorption”.

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5 comment threads

Conformal coatings? (1 comment)
FR-4 and soldermask will slowly absorb moisture (1 comment)
re: corrosion - if there is a path for current to another wetted metal also in contact with seawater,... (1 comment)
What's the application? (5 comments)
Vias? (5 comments)
What's the application?
Olin Lathrop‭ wrote 2 months ago

Do you really only need to know whether the water is up to a certain level, or are you ultimately trying to sense the level. If the latter, there are some technologies you might not be aware of. A company I work for specializes in measuring levels in tanks, and things like the draft of ships. We have off the shelf products, and some new ones in development, that can measure the level of rivers or the ocean.

misk94555‭ wrote 2 months ago

Olin Lathrop‭ The purpose of the electrodes is to measure conductivity (salinity). I’d like to cover the range from 0.1 to 50 mSiemens/cm (surface water, and seawater). I can settle for 0.1 to 8 mSiemens/cm (surface water only). The device will be completely submerged all the time.

misk94555‭ wrote 2 months ago

By the way, I’m going to use an LPS28 pressure sensor to measure depth. Correction for barometric pressure will be done during post-processing.

Olin Lathrop‭ wrote 2 months ago

I think keeping the electrodes clean will be a problem. Gold should be inert enough, even in seawater. But the chlorine in the salt has a way of getting into everything eventually. Soldermask might survive long term in clean water, but I'd really want to do accelerated aging tests before expecting it to survive years in seawater.

I tried measuring water conductivity once using graphite electrodes. I thought they wouldn't corrode. They didn't, but the readings weren't repeatable. The project moved on, and I never did figure out what was going on there.

misk94555‭ wrote 2 months ago · edited 2 months ago

Olin Lathrop‭ I like the idea of an accelerated lifetime test. If I sous vide the sensor in seawater for 2 months at 70°C, that should be equivalent to a year in the field. (Assuming the common rule of thumb that every 10°C accelerates damages by a factor of 2x). I could freeze it a few times along the way too, for a good measure.