Sunday, January 24th, 2010 Nigel Jones

Today’s’ post was prompted by an excellent comment from Phil Ouellette in a recent newsletter from Jack Ganssle. In a nutshell Phil was advocating strobing switches with an alternating voltage waveform, rather than a direct voltage in order to minimize corrosion and premature switch failure. This happens to be an area in which I have some experience and so I thought I’d extend the concept a little bit and also give you some food for thought.

The basic idea behind Phil Ouellette’s comments is that if one has a bias voltage between two pins (such as between switch contacts), and if this bias is always in one direction (i.e. DC), then the bias can act so as to drive an electrochemical reaction. The exact results of this electrochemical reaction vary (corrosion, dendrite growth etc.), but the net result is normally the same – namely an unwanted short circuit between two pins.

These problems arise particularly on products that have to operate in humid environments and / or products that have to spend a very long time under power over their expected operational life.

So what can be done about this? Well the most important thing to understand is that it is voltage gradient (volts per meter) that is the driving force in this problem and that furthermore, voltage gradient is a vector quantity and thus its direction is important. With this understanding, it should be clear that to minimize these types of problems, one has to minimize the integral of the voltage gradient over time. To do this one has three basic choices:

1. Minimize the voltage
2. Maximize the separation
3. Modulate the voltage

Let’s take a look at each of these in turn:

Minimize the voltage
Clearly technology is progressing in the right direction for us here, as 5V systems are rapidly becoming extinct and 1.8V systems becoming more common place. Thus all other things being equal, the voltage gradient between any two pins on a 5V system will be 2.8 times greater than on a 1.8V system. Thus if you are designing a system where corrosion is a concern you will do yourself a big favor for opting for as low a voltage system as you can. However, see the caveat below.

Note also that given that what counts is minimizing the voltage over time, it follows that you can normally improve the system performance by powering down systems that are not needed at any given time. This also of course saves you power and thus is a highly recommended step.

Maximize the separation
This is by far and away the toughest problem. Twenty years ago, ICs ran on 5V and had 0.1 inch lead spacing, giving a maximum voltage gradient between pins of 5 / 0.00254 = 1969 V/m. Today, a typical 1.8V IC has a lead spacing of 0.5 mm giving a maximum voltage gradient of 1.8 / 0.0005 = 3600 V/m. Thus the voltage gradient between pins on a typical IC has gone up – despite the decrease in the operating voltage. Thus if selecting a low voltage part means that you must use a fine lead pitch part, then you are almost certainly shooting yourself in the foot!

Other areas where you can increase separation without too much pain is in the selection of passive components. For example a 1206 resistor has a much lower voltage gradient than an 0402 resistor, and an axial leaded capacitor is usually preferable to a radially leaded device. As a result, when I’m designing systems that have potential corrosion issues I really prefer to use larger components. Of course this can put you into conflict with marketing and production.

Modulate the voltage