NDA Protected Application
Epoxy Encapsulation for Industrial Sensor Modules
Executive Overview
Kirkco engineered an epoxy encapsulation architecture for industrial sensor modules operating in harsh environments where moisture ingress, vibration, and thermal cycling can compromise signal integrity. The architecture delivers repeatable, void-free encapsulation while supporting multi-variant sensor production.
Business & Quality Drivers
Sensor manufacturers require stable output and long service life to meet uptime guarantees and reduce warranty exposure. Manual potting introduced variability in fill quality and cure behavior, leading to drift and early failures. A controlled encapsulation approach was required to standardize quality.
Process Requirements
The application required two-component epoxy encapsulation with precise ratio control, temperature-conditioned delivery, and defined shot volumes to ensure consistent coverage of sensitive elements and interconnects.
System Architecture
The encapsulation platform utilizes precision metering and mixing with point-of-application dispense. Temperature control across supply, metering, and mixing maintains viscosity stability and predictable flow into compact housings.
Controls & Validation
PLC-based controls manage recipes, ratio monitoring, and automated flushing. Validated process windows ensure repeatable encapsulation performance across sensor variants and production shifts.
Encapsulation Quality Framework Alignment
This application aligns with Kirkco’s encapsulation quality framework, standardizing ratio stability, thermal control, void mitigation, and validation practices across encapsulation programs. Reference: Encapsulating Quality – Application Architecture (Rev C).
Operational Performance
Implementation improved encapsulation uniformity, reduced scrap, and stabilized sensor performance under environmental stress.
Lifecycle & Scalability
The architecture supports future sensor designs, material changes, and throughput increases without redesign of the core platform.
Adhesives & SealantsTwo-Component Adhesive Metering & Mixing Systems