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The challenge electronics research labs, semiconductor manufacturing sites and medical device manufacturers face is how to keep highly sensitive electronic components from the risk of electrostatic discharge (ESD) while still maintaining the efficiency of the process. The standard off-the-shelf foam provides some level of protection or fit but it does not achieve ESD standards. The custom anti-static foam supplied by Shanghai Leenol is void of any such compromises. Leading electronics labs choose our custom foam solutions for the following reasons:
Precision Fit Eliminates Component Movement
Generic foam trays and foam inserts leave spaces around the components. This movement inside the container during shipping or automation can lead to contact with another component or the container wall. When a component touches another it can cause two distinct problems: a mechanical or impact shock to the component and the triboelectric charging of both components through frictional forces. While the foam may be ESD resistant, a charge will still build between the two components.
Our custom anti-static foam solutions from Leenol are cut to precisely match the geometry of each component cavity. Each and every component fits snugly within the pocket, preventing any shifting or movement. The perfect fit of the component in the foam also prevents mechanical damage. This perfectly snug fit eliminates the greatest cause of triboelectric charging within the container. It is critical that microprocessors, MEMS sensors and optical devices maintain perfect stability and are not moved around in the foam. Our CNC cutting machinery makes it possible for thousands of foam inserts to be manufactured to perfectly fit parts, repeatably and reliably batch after batch.
Multi-Layer Protection for Mixed Component Kits
There are instances within an electronics lab or semiconductor manufacturing facility where a number of types of components are grouped together in one container. Such items include a PCB assembly, connectors, wires, fasteners and ICs of all kinds, sensitive components can exist that are highly vulnerable. It is important that standard foam would not accommodate a kit with varying levels of sensitivity and different mechanical vulnerability.
Leenol can design custom multi-layer foam layouts for all mixed component kits. By incorporating varying degrees of density and different ESD properties into the same foam inserts, components receive varying degrees of protection. High density ESD foam around sharp components will provide sufficient strength to prevent any part from impacting and penetrating the surrounding foam. Delicate components are buffered using soft conformal ESD foam. Leenol can combine layers of these foam types side by side within the same container, or stacked above each other. Labs have found that by utilizing Leenol's custom foam kits they are losing fewer components due to ESD and are also able to sort and package components for kits more quickly because the parts are placed in a predetermined and logical sequence in the container.
Material Compliance with International ESD Standards
The top electronics labs that use our products have stringent quality management systems in place. They must have documented proof that the products being used in their ESD control program meet all relevant international standards. Not all standard foam suppliers can produce the appropriate documentation or prove its validity, and sometimes, even if it is, only certain thicknesses or specific batches are compliant.
Our custom anti-static foam solutions are all designed to be IEC61340-5-1 and ANSI/ESD-2020 compliant. We produce all foam in an ISO 9001 certified quality system. Our materials are tested and certified by SGS and RoHS and full compliance documentation will be shipped with every order. This is a requirement for labs serving automotive, medical, aerospace, or defense sector clients. This level of confidence that the laboratory has fully compliant ESD packaging provides lab managers with ease of mind during internal or customer inspections.
Short Lead Times for Rapid Prototyping and Production
Leenol maintains an express production service that has been specially developed for R&D clients. We will utilize your provided digital files (from a designer or even samples) to custom cut foam inserts using our state-of-the-art CNC equipment, rather than require many weeks. For time sensitive prototyping, express services are available. Once the design is validated by the lab, Leenol does not require retooling in order to produce large quantities, and guarantees a repeatable precise fit from prototype to production. This is why the most successful electronics labs return to Leenol time and again.
Conclusion
Leenol's customized anti-static foam is used by leading electronics labs for its precision fit that prevents components from moving, multi-layer configurations for multi-component kits, full compliance with international ESD standards, and the short lead time required for producing prototype parts. Shanghai Leenol has a full line of ESD solutions available including storage products, packaging, work station accessories, personnel protection items, clean room accessories and testing equipment. Leenol offers over 200 different product types that are made toIEC61340-5-1 and ANSI/ESD-2020 international standards, and conform to ISO 9001, SGS and RoHS requirements. Call Leenol today to discuss your unique custom foam needs and secure a precise fit ESD protection solution for your sensitive parts.
